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Landing gear beam

On the fuselage there are several structural components produced in titanium. Here is a landing gear beam that shows the main challenges for machining these types of structural components.

 



 

Dedicated titanium milling grades

S30T and S40T are available for a variety of CoroMill® cutters for face milling, shoulder milling, long-edge milling, plunging, high-feed milling, profiling and slot milling. Together these grades amount to a new level of reliable long lasting performance.

 
 

Grade S30T for speed and tool life

S30T has been developed with productive titanium milling in focus. It combines the properties of micrograin carbide and a wear resistant PVD coating. This enables very sharp cutting edges that resist fatigue and micro-chipping and result in cutting edges that are preserved for longer times in cut at higher cutting speeds. 

 

Grade S40T for difficult conditions

S40T is developed for difficult conditions combining high toughness cemented carbide with a thin CVD coating. The result is a grade that withstands vibration and other difficult cutting conditions for longer times in cut. The wear is predictable, making the cutting edge gradually duller without breaking.

Titanium milling grade S30T

 

 

 
 
 
 
 
 
 

 

 

 

 

 

 

 

 

 

​Finishing of 2D pocket

Perfect choice for finish machining of 2D pockets is the specialized solid carbide end mills.

These end mills developed for titanium enables you to machine deep pockets at high metal removal rates without vibration.

Other benefits are high accuracy and long tool life at high cutting data.

 

Corner milling-slicing

CoroMill Plura and slicing method is the ideal combination when machining corners in titanium components. Multiple passes successively remove material ensuring low radial immersion/engagement angle and low cutting forces.

Slicing corner

 

 

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Rough face milling

Program a roll into cut in a clockwise motion (counter-clockwise will not solve the thick chip thickness problem). By rolling into cut, the chip thickness on exit is always zero, allowing for higher feed and longer tool life. A round insert cutter provides best productivity and tool life thanks to the lead angle and chip-thinning effect. CoroMill® 300 with S30T and S40T has through coolant and close pitch option, therefore optimized for titanium. Now available in insert sizes up to 20 mm (metric) or 1.0’’ (inch). 


Entrance into cut

 

 
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Titanium milling grade S30T







 

2D profile milling

For this operation we can provide a total solution from roughing through to finishing. The best choice for roughing is CoroMill® 690 with specialized titanium grades S30T and S40T. The axial location of the inserts is built into the bottom of the insert to prevent movement and enable high metal removal rates with security. Its design makes it cut light and use minimum power. Each coolant hole is threaded to allow smaller diameter nozzles for high pressure coolant applications.

CoroMill 690
 
 
More videos:

Titanium milling grade S30T

 
 
 
 

For finishing we recommend the Sandvik Coromant long-edge finishing cutter, also known as the Dream cutter which gives a surface finish from 0.6 to 1.2 Ra where the steps on the surface are replaced by a slight wave.

The average flatness measures from 0.025 to 0.038 mm peak to valley.
 

 

 

 

High pressure coolant

 

Trouble-free production with targeted coolant​
 

The recommendation here is simple, always apply coolant when cutting titanium in large amounts and if possible at high pressure. Using high pressure coolant for milling in titanium will double the tool life compared to normal coolant pressure. The critical re-cutting of chips that damages the tool is prevented as welded chips are blown off.

 Recommendations:
  • Apply coolant through spindle and tool
  • Volume and pressure should be carefully planned in relation to the number and diameter of coolant holes and your operation
  • Nozzle sizes should be kept small to maximize pressure
  • Recommended pressure: 70 bars or more
  • Recommended volume: 50 litres/minute
 


High pressure coolant

 
 
 


Roughing of 2D pocket - Solution 1

For roughing of the 2D pocket apply the circular ramping method using low depths of cut but up to 1.0 mm feed per tooth together with the high feed cutter CoroMill 210 which provides a light and fast technique with excellent metal removal rate. It is suitable for all machine concepts and configurations.

The advantages with this circular ramping method are reduced number of tools (no drills needed), flexiblity - can produce a wide range of sizes. Alternative tools using the same programming technique are round insert cutters such as CoroMill 300 and CoroMill 200.

 


Roughing of 2D pocket -Solution 2

Opening up a 2D pocket with spiral morphing method using the CoroMill 390 long edge with 11 mm size insert and new titanium grade S30T provides excellent metal removal rates. Keep arc of engagement low when pocketing - produce a large entering hole (made by either drilling or helical ramping), roll into cut, then program with large corner radii to avoid vibration in corners.

Read more about CoroMill 390




 

 

Continous ramping

 

 

CoroMill 210
 

 

CoroMill 300

 

 Spiral morph
 
 

CoroMill® 690 with new grade S30T

Component: Pylon
Operation: Roughing shoulder
Material: Ti-6Al-4V, 350 HB, forged, through hardened
Tool: Competitor / R690-10 Dc 80 int
Coolant: High pressure coolant

Competitor

S30T

​Cutting speed, vc (m/min)
​73
​60
​Rpm
​290
​238
​Table feed Vf (mm/min)
​232
​232
​z
​5
​5
​Feed/ tooth, fz
​0.16
​0.19
​Max chip thickness, hex mm
​0.12
​0.16
​Depth of cut, AP mm
​45
​45
​Radial depth of cut, ae mm
​10
​10
​Tool life (min)
​60
​84
​Tool life (components)
​10
​14

​Result: CoroMill 690 equipped with grade S30T makes 40% more parts than competitor.

 
 
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