Metal cutting solutions for aerospace innovation
Sandvik Coromant — the aerospace industry’s trusted partner.
Many of the advances we see in the aerospace sector have material innovation at their core. Whether the drivers for change are sustainability, efficiency or the introduction of digital tools, aerospace manufacturing relies on the development of new technologies and materials to build the aircraft of the future. As a close partner of the aerospace industry, metal cutting leader Sandvik Coromant has been a link between machining knowledge and tooling solutions since 1942.
The Wright brothers’ first flight in 1903 may have lasted just twelve seconds before the plane reached the ground, but it marked the take-off for over a century of research and development in the aerospace sector. Since the flight of the world’s first successful motor-operated plane, aerospace manufacturing has adapted to overcome many more challenges.
New materials play a key role in overcoming aerospace challenges. But bringing new materials into research and development invites its own set of difficulties. As a result, aerospace manufacturers must partner with experienced, knowledgeable tool providers to help them navigate new demands.
A new era
The main challenge for the early 20th century aerospace industry was simply getting planes up in the air. Now, several new requirements have been placed on manufacturers. Pressure to lower air travel’s carbon footprint has placed an emphasis on making planes lighter, in order to save on fuel.
Shedding weight will help bring down the high fuel consumption of planes. For instance, when United Airlines switched its in-flight magazine to lighter paper, it saved over 170,000 gallons of fuel a year. Every gram counts when making aircraft lighter, from large components such as the wing box, to intricate motors in reclining passenger seats. Moving towards more fuel efficient aircraft will also play a major role in fuel reduction, with the roadmap leading to fully electric aircraft underway.
Elsewhere, the maintenance, repairs, and operations (MRO) part of the aerospace industry has been one of its more complex aspects. As a result, many manufacturers have looked for ways to reduce maintenance costs. Much of this is being tackled by simulated data, which allows airlines to plan their maintenance and repairs ahead of time.
Aerospace turbine disc component in HRSA.
Advances in materials have led to a variety of possibilities for aerospace companies. This has been seen through the increased use of composites and graphene, and also lightweight materials such as titanium. Other innovations in materials technology include the use of metal powers and additive manufacturing technologies to design lightweight and more sustainable metal parts.
Titanium is 30% stronger than steel, but nearly 50% lighter — making it a key component in addressing efficiency and sustainability challenges. However, machining materials such as titanium presents its own challenges. Titanium alloys can have double the hardness of steel alloys so, when paired with titanium’s low thermal conductivity, high thermal and mechanical loads are placed onto the tools tasked with cutting the metal.
A trusted partner
With an established history working with the aerospace industry, Sandvik Coromant has evolved alongside its innovations and challenges, and will continue to support as the industry moves towards new trends. With more than 1800 patents in its portfolio today, Sandvik Coromant can provide tools and solutions together with in-depth application know-how. With a strong foothold in research and development, and close cooperation with both customers and machine builders, Sandvik Coromant has a truly competitive offer to bring to the aerospace industry.
For instance, Sandvik Coromant invests heavily into developing tools specifically for difficult to machine materials. High feed side milling is an effective method for machining challenging materials. Small radial engagement allows for increased cutting speed, feed and cutting depth due to decreased heat, chip thickness and radial forces. The CoroMill® Plura range of tools is just one example of Sandvik Coromant’s offering that’s specially developed for heat resistance super alloy (HRSA) materials.
High feed side milling with CoroMill Plura.
In addition to equipping aerospace manufacturers with the right physical tools, Sandvik Coromant understands the need for digital tools that can streamline operations and enhance productivity. For many aerospace manufacturers, having the right tools at the right time can be challenging. Planning for availability in a workshop requires transparency into all operations. While manual collection of data and documentation becomes tedious and time-consuming, a connected approach offers new possibilities for transparency, optimized planning and a streamlined production.
Sandvik Coromant’s CoroPlus® Machining Insights places data at a manufacturer’s fingertips, helping to improve workshop efficiency and overall equipment effectiveness. With instant access to information such as tool use, machine data and process performance, a vital part of aerospace MRO activity, tool use, can become significantly more streamlined.
The aerospace industry has amassed over a century of innovation, making the previously impossible a reality. Yet it still faces constant change, and must continue to adapt to the shifting demands of our society. Remaining competitive doesn’t only require a sound knowledge of industry trends — understanding the materials and technologies at the core of aerospace innovation is key to high flying success.
