On the fuselage there are several structural components produced in titanium. The landing gear beam is one example of a component with thin floor sections.
Machining of structural aerospace components often involve challenging conditions, such as thin floors and walls, deep pockets and tight corners. We help you overcome these challenges with dedicated tools and methods.
Common challenges when machining structural parts:
- Poor productivity
- Deflection of the tool and component
- Short tool life
- Chip jamming
- Time consuming process
Stable high feed side milling strategy
Tough milling strategies with large tool engagement build up heat and cause excessive cutting forces which is challenging for the tool. A more stable strategy is to program for a large cutting depth (ap) and low cutting width (ae) combined with controlled maximum chip thickness to control the cutting forces. This allows for high feed machining with increased cutting speed and feed to achieve a high metal removal rate.
By utilizing a high feed side milling strategy, you will get a stable process and improved metal removal rate (Q).
This is how Q changes with different cutting widths (ae), cutting depths (ap), and chip thickness (hex) in the graph.
Read more about CoroMill® Plura HFS ISO S
Read more about CoroMill® 316
When machining thin floor sections, the cutting forces acting in the z direction will push the floor down. The forces easily forms deformation of the pocket.
The distribution of cutting forces depend on several factors:
- Number of engaged teeth (z)
- Radial depth of cut (ae)
- Axial depth of cut (ap)
- Helix angle
- Control of cutting forces
- Deflection of floor
- Distortion of part
- Surface finish
- Residual stress from machining
To overcome the thin floor machining challenges, Sandvik Coromant has developed a dedicated machining strategy:
- Spiral morph tool path for maximising part stability to reduce floor deflection
- Optimised remaining stock to achieve finish cut with minimised axial cutting forces
- Corners machined with a slicing method
- Optimised ap/ae relationship to minimise cutting forces and component deflection