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AEROSPACE APPLICATIONS INDEX AEROSPACE AIR FRAME Y CFRP Y CFRP/AI Y CFRP/Ti Tool Page

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AEROSPACE APPLICATIONS INDEX AEROSPACE AIR FRAME Y CFRP Y CFRP/AI Y CFRP/Ti Tool Page A614G AEROSPACE APPLICATIONS INDEX AEROSPACE AIR FRAME y CFRP y CFRP/AI y CFRP/Ti Tool Page Drilling MCC Drill 5 Drilling MCA Drill 6 Trimming DFC End Mill 7 y Aluminium Alloy y Aluminium-lithium Alloy Face Milling, Pocket Milling AXD Series 8 Face Milling, Pocket Milling AXD Series 9 Face Milling, Pocket Milling ALIMASTER 10 Exchangeable Head End Mills Face Milling, Pocket Milling iMX Series 11 y Titanium Alloy Side Milling, Rough Pocket Milling VFX Series 12 Face Milling, Side Milling AJX Series 13 Side Milling, Pocket Milling ARP Series 14 VQT5MVRB Slotting Corner Radius End Mill for High Effi ciency Titanium Alloy Machining 15 Side Milling, Pocket Milling Coolstar Series 16 y Precipitation Hardening Stainless Steel Rough Pocket Milling VPX Series 17 Drilling MMS Drill 18 2 ENGINE y Ni-based Superalloy Tool Page LS/MJ/MS/MA/RS External, Face and Internal Turning MP9005/MP9015/MP9025 20 External, Face and Internal Turning US905/VP05RT/VP10RT 21 Copy Turning GY Series 22 Machining of Upper Surface of Protuberance APX Series 23 Drilling (Helical), Profi le Milling ARX/ARP Series 24 Drilling (Helical), Profi le Milling CERAMIC End Mill 25 SMART MIRACLE Finish Profi le Milling Vibration Control Ball Nose End Mill 26 VQT6UR Finish Profi le Milling Barrel End Mill for Finish Cutting of Titanium Alloys 27 Drilling MMS Drill 28 y Titanium-aluminium Alloy SMART MIRACLE Finish Profi le Milling End Mill Series 29 y Titanium Alloy External, Face and Internal Turning LS/MS/RS MT9005/MT9015 30 y Maraging Steel External, Face and Internal Turning FJ/MJ/MS/GJ VP05RT/VP10RT/VP15TF 31 External, Face and Internal Turning JT Holder 32 LANDING GEAR y Titanium Alloy Rough Milling VFX Series 34 Rough Pocket Milling APX Series 35 SMART MIRACLE Finish Profi le Milling Vibration Control Ball Nose End Mill 36 Exchangeable Head End Mills Finish Pocket Milling iMX Series 37 Exchangeable Head End Mills Finish Pocket Milling iMX Series 38 Drilling MNS Drill 39 3 Air Frame 4 AIR FRAME Work Materials [CFRP] New CVD diamond coated drills Optimized cutting geometry Drilling MCC Drill (Leafl et P713G) Key Point on Machining a A 90°point angle is used to reduce thrust when drilling, this prevents delamination and also improves hole tolerance. Application Example Drill ø 6.55 Cutting Speed vc120 m/min (n5840 min-1) Feed f0.10 mm/rev Machine Vertical type M/C Coolant Dry cutting Comparison of Tool Life and Hole (Entrance/Exit) *The tool life determination depends on the chipping After 820 holes machining MCC A 1.6 times MCC B longer tool life Can continue Conventional 0 200 400 600 800 1000 1200 1400 1600 (Holes) <Cutting condition> Cutting speed : 120m/min Tool : ø6.55 Feed : 0.10mm/rev Work material : CFRP Cutting mode : Dry cutting Chipping For tool life (10mm) Conventional For hole quality (12.5mm) 306 holes 588 holes MCC MCC ConventionalMCC Conventional (1192 holes) Entrance Exit 5 AIR FRAME Work Materials [CFRP, CFRP/Al] New CVD diamond coated drills Unique groove design Drilling MCA Drill (Leafl et P713G) Key Point on Machining a A unique flute design is employed to prevent the aluminium chips from damaging the finish of the CFRP section thus reducing the gap in hole size between the aluminium and CFRP section. Application Example Drill ø 6.38 Work Material CFRP + Aluminium Alloy Cutting Speed vc100 m/min (n5000 min-1) Feed f0.15 mm/rev Machine Vertical type M/C Coolant Internal air Groove Shape Effect MCA Conventional (μm) (μm) *Enlarged view 100 100 X Entrance (CFRP) X Center (CFRP) X Exit (Al) X Entrance (CFRP) X Center (CFRP) X Exit (Al) 80 Y Entrance (CFRP) Y Center (CFRP) Y Exit (Al) 80 Y Entrance (CFRP) Y Center (CFRP) Y Exit (Al) Back Counter Occurrence 60 60 CFRP CFRP 40 40 Al 20 20 Al 0 0 *Hatching: Required hole precision -20 -20 Outside the hole tolerance standards (5 holes) -40 -40 1 50 100 150 200 250 15 (Holes) (Holes) <Cutting condition> Tool : 0.251”(ø6.38) CFRP Al Work material : CFRP(11mm)+Al(5mm) Cutting speed : 100m/min Cutting speed : 100m/min Feed : 0.15mm/rev Feed : 0.15mm/rev Cutting mode : Internal air 6 AIR FRAME Work Materials [CFRP] New CVD diamond coated end mills Optimized cutting geometry Trimming DFC End mill (TOOLS NEWS B189G) Key Point on Machining a Tool life is generally short due to the high strength of the carbon fibres, and also due to the fact that delamination and burrs develop easily. Therefore the DFC end mill range employs a CVD diamond coating and a cutting edge geometry that prevents these problems and prolongs tool life. Application Example a The combination of the CVD coating and the cutting edge prevents problems relating to burrs and delamination. Trimming Hole Expansion End mill DFC4JCD1000 (ø10) End mill DFC4JCD1200 (ø12) Work Material CFRP Work Material CFRP n6000min-1 n2390min-1 Revolution (vc188m/min) Revolution (vc90m/min) vf750mm/min vf382mm/min Feed (fz0.03mm/tooth) Feed (fz0.04mm/tooth) Depth of Cut ap5mm Depth of Cut ap18mm, ae2.0mm & 0.5mm Coolant Air blow Coolant Air blow DFC4JCD1000 96 Holes No burr formation Tool Cutting direction Conventional Machining path ø25.4 mm→ø30.4 mm 30.31 mm Burr formation Flank wear after 96 holes machining Cutting direction Can continue 7 AIR FRAME [ ] Work Materials Aluminium Alloy Convex cutting edge Helical fl ank Low cutting resistance Face Milling, Pocket Milling AXD Series (TOOLS NEWS B116G) Key Point on Machining a Machining of these kinds of components means machining from block, whereas much as 90% of the material needs to be removed. As such it is necessary to carry this out as fast and efficiently as possible. The AXD series uses inserts that have a suitable relief that results in lower cutting resistance. Also a convex cutting edge is used to improve the overall chip disposal. The combination of which result in the tool to be able to be used for high speed and high efficiency machining. Application Example a Metal removal rate of 10,000cm3/min can be achieved when using the AXD7000-HSK. Holder AXD7000R05003A-H63A Insert (Grade) XDGX227030PDFR-GL (TF15) Work Material A7075 Cutting Speed vc2830 m/min (n18000 min-1) Feed fz0.21 mm/tooth (vf11340 mm/min) Depth of Cut ap18 mm, ae50 mm Coolant Emulsion Point Avoids poor wall surface finishes because the tool is designed to interpolate corners of the pocket, thereby also preventing vibration. ap18mm ae50mm 8 AIR FRAME [ ] Work Materials Aluminium-lithium Alloy Convex cutting edge Helical fl ank Low cutting resistance Face Milling, Pocket Milling AXD Series (TOOLS NEWS B116G) Key Point on Machining a For higher cutting speed ranges the use of the MP9120 is recommended. Application Example a For the machining of Aluminium-lithium alloys the GM breaker in combination with the tool grade MP9120 is recommended. This results in reduced chipping and stable machining. Holder AXD4000-050A04RA Insert (Grade) XDGX175024PDER-GM (MP9120) Work Material Aluminium-lithium Alloy Cutting Speed vc4712 m/min (n30000 min-1) Feed fz0.1 mm/tooth (vf12000 mm/min) Depth of Cut ap6 mm, ae50 mm Coolant Emulsion GM Breaker Tool life (Number of work pieces) 0 1 2 3 GM breaker (MP9120) Conventional 3 times 9 AIR FRAME Work Materials [Aluminium Alloy] Instability in chip Smooth chip separation separation Chip fl ow Chip fl ow Competitor Mitsubishi Face Milling, Pocket Milling Improved chip removal ALIMASTER (TOOLS NEWS B118G) Key Point on Machining a The ALIMASTER series employs a unique cross section geometry that enables effective chip removal properties. The overall result of which is that it can be used to machine with higher speeds and increased efficiency. Application Example a Metal removal rate of 5,000cm3/min can be achieved when used on machines with sufficient power. End mill CSRARBD2500R300 (ø 25/R3) Work Material A7075 Cutting Speed vc1178 m/min (n15000 min-1) Feed fz0.22 mm/tooth (vf10000 mm/min) Depth of Cut ap25 mm, ae20 mm Coolant Emulsion Point Avoids poor wall surface finishes because the tool is designed to interpolate corners of the pocket, thereby also preventing vibration. <Machine specifi cation> 15000min-1/75kW, BT50 ap25mm ae20mm 10 AIR FRAME Work Materials [Aluminium Alloy] High Precision High Rigidity Face Milling, Pocket Milling Low Cost Exchangeable Head End Mills iMX Series (TOOLS NEWS B200G) Key Point on Machining a The iMX exchangeable heads specific for machining aluminium alloys employs a large rake angle and polished cutting edges to result in a sharper cutting edge to reduce cutting resistance and to prevent problems relating to welding. Application Example a When the iMX head is used with a carbide arbor this results is high rigidity and prevents vibration even when carrying out slotting applications. Head (Grade) IMX10S3A10008 (ET2020) Holder IMX10-U10N014L070C Overhang length 35 mm Work Material A7075 Cutting Speed vc408 m/min (n13000 min-1) Feed fz0.12 mm/tooth (vf4680 mm/min) Depth of Cut ap5 mm, ae10 mm Coolant Emulsion Effi ciency (%) 050100150 Wall surface iMX Bottom face Wall surface Conventional 1.5 times Bottom face 11 AIR FRAME Work Materials [Titanium Alloy] Arranging the inserts vertically Cutting force V formation of the clamping face Side Milling, Convex curve Rough Pocket Milling cutting edge VFX Series Key Point on Machining (TOOLS NEWS B182G) a When rough machining of titanium alloys problems such as chipping and abnormal damage can occur if using tools with low rigidity. The VFX series offers a design that has high rigidity and also insert geometry that employs a convex cutting edge to improve cutting edge stability.
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