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    Tooling

    Taking the difficulty out of aerospace parts

    • By MTDCNC
    • July 13, 2021
    • 4 minute read

    For aerospace manufacturers with the daily challenge of machining difficult materials coupled with perplexing geometries, Quickgrind is on hand to provide the suitable cutting tool and technical support to simplify challenges. Here, Mike Stobart from Quickgrind discusses how the Tewkesbury cutting tool manufacturer is supporting industry through its ‘Infinite Possibilities’.

    The aim here is to highlight some of the Quickgrind ranges that have recently been applied to a typical TiAL64V Grade 5 titanium mating spline flange. The tools and strategies will hopefully provide manufacturers something to consider when machining similar components.

    Concentrating on roughing and finishing possibilities with this mating spline flange, we are bringing attention to our solid carbide cutters such as the new Mirage Super, Spectre and Phantom high feed tools and our highly cost-effective Eliminator conical barrel tools.

    The Mirage range is being successfully used in a wide range of applications and with this component, we are using the latest addition to the range, our Mirage Super. It utilises the latest micro grain carbide, XRed-SL coating and in this instance, a 20mm Mirage Super with 5 flutes and 1mm radius is applied to trochoidal mill outer pockets with a 6% stepover and a 35mm depth of cut. This strategy enables full flute engagement reducing the number of step downs to shorten cycle times. Having chip breakers (which are available on virtually all our tools) the swarf generated is very small and this alleviates any issues with swarf clearance.

    Following this tool, we apply a 12mm Mirage Super tool with 6 flutes and a 40mm flute length with 1mm radius to finish profile the outer pockets at 3XD. Often, it is hard to obtain tools with longer flutes, but this is something we specialise in. At Quickgrind, we work with our customers to produce optimised tools for all applications.

    Solid carbide high feed tools permit higher feeds and small depths of cut to produce a secure method of rapid metal removal. In this case, we are using an 8mm Spectre 3-flute end mill to machine the clearance area on lower pockets. This is completed with a 0.4mm depth of cut and a 50% step over rate. Our Spectre range is available from 1.5mm to 12mm diameter in short, medium or long length, with or without through coolant. Our ‘Infinite Possibilities’ programme means that we will produce a tool to service your application.

    We have four types of high feed tools. This includes the Spectre, Bulldog, Reaper and Phantom – all developed for the ever-increasing demands placed upon high-performance tooling. With this component, we used a 12mm Phantom 4-flute to helical drill for the taper tool to drop into. The Phantom range is available from 10 to 25mm and is one of the only high feed tools capable of being remanufactured a number of times, giving great cost savings.

    The follow-on tool is our versatile 5-degree taper to trochoidal rough mill the centre pocket at a 5% stepover. We produce thousands of taper tools in a huge array of designs from taper angle to flute length options, with square or ball ends. We carefully select the appropriate solid carbide and coating designation to deliver performance on tools that can be remanufactured up to 11 times.
    If you have never used a barrel tool or you are unsure where they can be used, then you need to talk to us. In this example, a 12mm barrel tool finishes the internal bore/cone with a 4mm stepdown. Normally, this would be a ballnose using a 0.25mm step down with a much higher cycle time.

    From here, we revert back to our Mirage tools. This time we are using the 10mm Mirage with a shortened flute length and 0.5mm corner radius to rough and finish the spline bore with spiral pocket milling. The Mirage in its original form has been the ‘go-to’ tool for many aerospace customers.

    To rough the spline teeth, we produced a 2mm 3-flute Spectre end mill with 40mm reach and this was finished with a 1.5mm. As you would expect from one of the UK’s leading manufacturers of solid carbide tools, we produce a huge variety of tools. Some may be relatively simple, such as a 6mm chamfer tool to chamfer the lower pockets and 5mm drill chamfer combination (subland) to drill and chamfer the top holes. Then our M6X1mm pitch threadmill for the top holes. The final tool is a 4-flute ballnose Zodiac. This is a 3mm R1.5 tool used to produce the top internal radii.

    https://cdn.mtdcnc.global/cnc/wp-content/uploads/2021/07/08145245/MAGAZINE-DEMO-RENDER-PNG-5-no-background-640x360.png

    Taking the difficulty out of aerospace parts

    For aerospace manufacturers with the daily challenge of machining difficult materials coupled with perplexing geometries, Quickgrind is on hand to provide the suitable cutting tool and technical support to simplify challenges. Here, Mike Stobart from Quickgrind discusses how the Tewkesbury cutting tool manufacturer is supporting industry through its ‘Infinite Possibilities’.

    The aim here is to highlight some of the Quickgrind ranges that have recently been applied to a typical TiAL64V Grade 5 titanium mating spline flange. The tools and strategies will hopefully provide manufacturers something to consider when machining similar components.

    Concentrating on roughing and finishing possibilities with this mating spline flange, we are bringing attention to our solid carbide cutters such as the new Mirage Super, Spectre and Phantom high feed tools and our highly cost-effective Eliminator conical barrel tools.

    The Mirage range is being successfully used in a wide range of applications and with this component, we are using the latest addition to the range, our Mirage Super. It utilises the latest micro grain carbide, XRed-SL coating and in this instance, a 20mm Mirage Super with 5 flutes and 1mm radius is applied to trochoidal mill outer pockets with a 6% stepover and a 35mm depth of cut. This strategy enables full flute engagement reducing the number of step downs to shorten cycle times. Having chip breakers (which are available on virtually all our tools) the swarf generated is very small and this alleviates any issues with swarf clearance.

    Following this tool, we apply a 12mm Mirage Super tool with 6 flutes and a 40mm flute length with 1mm radius to finish profile the outer pockets at 3XD. Often, it is hard to obtain tools with longer flutes, but this is something we specialise in. At Quickgrind, we work with our customers to produce optimised tools for all applications.

    Solid carbide high feed tools permit higher feeds and small depths of cut to produce a secure method of rapid metal removal. In this case, we are using an 8mm Spectre 3-flute end mill to machine the clearance area on lower pockets. This is completed with a 0.4mm depth of cut and a 50% step over rate. Our Spectre range is available from 1.5mm to 12mm diameter in short, medium or long length, with or without through coolant. Our ‘Infinite Possibilities’ programme means that we will produce a tool to service your application.

    We have four types of high feed tools. This includes the Spectre, Bulldog, Reaper and Phantom – all developed for the ever-increasing demands placed upon high-performance tooling. With this component, we used a 12mm Phantom 4-flute to helical drill for the taper tool to drop into. The Phantom range is available from 10 to 25mm and is one of the only high feed tools capable of being remanufactured a number of times, giving great cost savings.

    The follow-on tool is our versatile 5-degree taper to trochoidal rough mill the centre pocket at a 5% stepover. We produce thousands of taper tools in a huge array of designs from taper angle to flute length options, with square or ball ends. We carefully select the appropriate solid carbide and coating designation to deliver performance on tools that can be remanufactured up to 11 times.
    If you have never used a barrel tool or you are unsure where they can be used, then you need to talk to us. In this example, a 12mm barrel tool finishes the internal bore/cone with a 4mm stepdown. Normally, this would be a ballnose using a 0.25mm step down with a much higher cycle time.

    From here, we revert back to our Mirage tools. This time we are using the 10mm Mirage with a shortened flute length and 0.5mm corner radius to rough and finish the spline bore with spiral pocket milling. The Mirage in its original form has been the ‘go-to’ tool for many aerospace customers.

    To rough the spline teeth, we produced a 2mm 3-flute Spectre end mill with 40mm reach and this was finished with a 1.5mm. As you would expect from one of the UK’s leading manufacturers of solid carbide tools, we produce a huge variety of tools. Some may be relatively simple, such as a 6mm chamfer tool to chamfer the lower pockets and 5mm drill chamfer combination (subland) to drill and chamfer the top holes. Then our M6X1mm pitch threadmill for the top holes. The final tool is a 4-flute ballnose Zodiac. This is a 3mm R1.5 tool used to produce the top internal radii.