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Wing rib

There are several types of aluminium components on an aeroplane such as spars, skins, and ribs. The wing rib as an example shows some of the machining challenges such as thin walls/bases, 2D pockets and the importance of balanced tools.



 

Thin wall machining

The machining strategy for thin wall sections should vary depending on the height and thickness of the wall. The number of passes will be determined by the wall dimensions and axial depth of cut.

Use of high speed techniques, i.e small ap/ae and high vc facilitates milling of thin walls, as they reduce the time of tool engagement and consequently the impulse and deflection. Step support machining the wall in overlapping passes is used when wall thickness vs height are 15:1 to 30:1.



Pocketing with RAL 90

The RAL90 high speed aluminium milling cutter is optimized for heavy roughing to semi-finishing with excellent surface quality. Designed for high power spindles, RAL90 offers unique metal removal rates. The accuracy of the insert seat interface secures the position of the cutting edge, minimizing total tool run-out.

 

Corner milling - slicing

Slicing is a method used in corner milling where multiple passes successively remove material ensuring low radial immersion/ engagement angle and low cutting forces. By applying the dedicated aluminium geometries for CoroMill® Plura or CoroMill 316 with high speed machining techniques, extreme productivity increases can be made.


Slicing corner

 

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Roughing 2D pocket

CoroMill 790 with new dedicated geometry and circular ramping method is an ideal combination when roughing 2D pockets in aluminium. With inserts firmly secured by a unique design of the support face in the insert seat, possible consequences of high radial forces, generated at high speeds, can be eliminated. This insert security also guarantees accurate location of the cutting edges - almost eliminating insert tolerance errors and thus any resulting run out.

Read more about CoroMill 790

Light cutting geometry for high speed aluminium machining

 

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Engineered solutions

In the competitive world of manufacturing, demands for shorter lead times, increased specialization and more complex designs appear as challenges for us in providing productive engineered solutions. As a solution provider our experience in engineered solutions has enabled our customers to reduce the number of operations and machine cycle time as well as increase component quality.

Furthermore, as a result of early involvement in machine procurement activities, engineered solutions can contribute to a faster return on investment. Continued focus on major industry segments drives our future development of the engineered product offer to comprehensively support your total machining requirements wherever they are in today’s and tomorrow’s global world of manufacturing.

 

3D models

 

​Tool balance

 
 
 

Efficient metal cutting requires that the movement of the cutting edge is precisely controlled, highly accurate and remains consistent. All forces which could disturb this control must be assessed and dealt with, including those which arise from the high speed rotation of the cutter itself.

The mass of the cutter and tool holder must be evenly distributed around its rotational axis otherwise the unbalanced centrifugal forces created will cause deflection and vibration.

 
 

The consequences of balancing to G2.5


Taper 40 tool balanced with an added sticker


  • Sticker 25 x 50 mm. m = 0.25 g
  • Mass of tool mtool = 1.25 kg
  • Radius to sticker r = 20 mm
  • u = m * r = 5.0 gmm
  • e = u/ mtool = 4.0 μm
  • Balance class at 15 000 rpm
  • e * n/ 9549 = G6.3
  • Unbalance force at 15 000 rpm
  • u * (n/ 9549)2 = 12 N

 


 

 

     
 
 
 
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