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Aerospace

Combustion casing

Typically made from inconel or waspalloy, these most challenging of materials pose problems, not so much in the turning operations, but particularly with the amount of milling required in manufacturing this component and the large amounts of material to be removed.

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Rough milling around a boss

For productive secure machining use CoroMill® 300 with a roll in programme combined with round inserts to reduce notch wear and allow high feed rates.

Read more about CoroMill 300

CoroMill 300

 

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​Helical ramping a hole from solid

Helical ramping of larger diameter holes with CoroMill® 300 provides the most secure and productive method here.

The cutting forces are much lower than drilling, which also struggles with the interrupted exit into the bore.  

Ramping down to 32 mm (1.260 in) hole diameter is possible and CoroMill 300 also comes with the advantage of Coromant Capto® coupling and through spindle coolant.

Read more about CoroMill 300

For best results, we recommend you contact your representative to get this right from the start.

 

Helical ramping

 

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Dramatic productivity increase with ceramic turn milling

 

To be successful with this type of application careful process planning is required. Unlike the conventional optimized method with carbide, ceramic face milling runs at a speed of 1000 m/min (3281 ft/min), removing the same amount of metal but 5 times faster.

For best results, follow the guidelines of our dedicated HRSA application guide.

Read more about our ceramic grades for HRSA

 

 
​​Ceramic​Carbide
​Application​Conventional/up millingClimb milling​
​Coolant​Dry​Wet
​Insert​RNGN 120700 E 6060​CM300-1204E-MM 2040
​Cutting speed, vc m/min (ft/min)
​1000
(3281)
​30
(98)
Diameter, D3 mm (in)​
​63
(2.480)
​63
(2.480) 
​Spindle speed, rpm5052152
Feed rate, fz mm/tooth​ (in/tooth)
​0.1
(0.004)
​0.3
(0.012)
​Number of teeth, Zn4​​6
​Depth of cut, AP mm (in)
​1.5
(0.059)
​2
(0.079)
​Radial immersion, ae mm (in)
35​
(1.378)
​35
(1.378)
​Metal removal rate, Q cm3/min (in3/min)
​106
(6.469)
​19
(1.159)
​Tool life, TL mins​4​25
Total material removed, Qt cm3​ (in3)
424​
(25.874)
​477
(29.108)
 
 

 

Ceramic milling
 

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​The complete modern hole making solution

Drill with CoroDrill® 846

The latest development in solid carbide drill technology with geometry optimized for HRSA offers a high number of drilled holes with security and low axial cutting forces.

Secure drilling for thin walled components



Finish bore with CoroMill® Plura end mill

Circular interpolation is a fast and secure method, one tool can finish a wide range of hole diameters, reducing tool inventory.

Read more about CoroMill Plura



Reliable threading and tapping

The new threading and tapping solutions for nickel base alloys provide excellent process security on high value components.

  • Reliable tool life
  • Reduction of machine downtime
  • Robust products reducing need for rework

Read more about CoroMill Plura thread mills

Read more about the CoroTap® families



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Reaming

Utilize the optimized geometries for productive reaming of HRSA materials:

  • D300 for titanium-based alloys
  • CoroReamer 835 -MF for nickel-based super alloys

There are two flute solutions available:

Spiral flute
  • For through-holes
  • Radial coolant-holes
  • Left-hand helix
  • Chips are pushed forward



Straight flute
  • For blind-holes
  • Central coolant-hole
  • Chips removed up the flute


Chamfer with Coromant Capto CoroTurn XS

This tool replaces inflexible special tools and can even be used for all de-burring and not just holes.

 

Chamfering of holes with CoroTurn XS

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​High feed side milling with CoroMill® Plura HFS, ISO S

Utilize the new CoroMill® Plura HFS families for reliable and productive milling. The optimized grade for nickel based alloys have sharp, controlled cutting edges, providing long and predictable tool life along with high metal removal rate.

 
 

 
 

Grade GC1105 – designed for the challenge of super alloy machining 

GC1105 provides secure, reliable, quality machining, even flank wear and is truly versatile in all application areas.
  • Reliability in intermediate stage machining through superior notch wear resistance in combination with good edge line toughness.
  • Guaranteed accurate high quality performance in last stage machining provided by our razor sharp, ground inserts and our state of the art thin coating, with excellent adhesion.
Precision machining with GC1105

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Ceramic turning

Ceramic grades CC6220 and CC6230 are designed specifically for the challenges of new HRSA materials where whisker ceramics and SiAlONs fall short, capable of higher cutting speeds, contributing to reduced cost per component. For high metal removal rates in pocketing and profiling applications, choose grade CC6160.

 
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