Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components
By Jorge Salguero, Irene Del Sol, Alvaro Gomez-Parra and Moises Batista
Published: October 6th 2020
DOI: 10.5772/intechopen.93719
https://www.intechopen.com/online-first/machining-of-al-cu-and-al-zn-alloys-for-aeronautical-components
CASE STUDY: NEW ALUMINUM ADVANCED PRODUCTIVITY ROUGHERS – S-CARB APR
KYOCERA SGS Precision Tools. Apr 01, 2020
The S-Carb Advanced Productivity Rougher (APR) was engineered for high power, high-efficiency machining of aluminum aerospace structural parts. Material removal rates of 550 cubic inches are achievable with remarkable tool life and product finish. The APR's MRR capabilities are nearly six times that of its nearest competition based on lab testing.
How Triumph Structures Increased Productivity?
Triumph Structures–Wichita invested in the first Makino A6 in the United States. With this 5-axis aluminum machining center in production since July, Triumph has exceeded its goals in three ways:
- Lowered cycle times by more than 50 percent for aluminum parts previously processed on a gantry-style vertical machining center
- Reduced part changeover and setup times from hours to minutes on some applications, thanks to the duel automatic pallet changers on the A6
- Increased peak metal removal from 80 cubic inches per minute to more than 500 cubic inches per minute
https://www.makino.com/resources/content-library/case-studies/advanced-aluminum-machining-technology
2020-01-17
Machining aluminum for lighter and better recyclable vehicles.
Sandvik Coromant has a complete offering for machining aluminium, from first-stage cubing, through roughing, semi-finishing and finishing.
The power train of a European passenger car typically contains around 80 kilograms of aluminium, which means these parts – the engine, gear box, suspension parts, housings – are an obvious area of interest for light weighting measures.
Several transmission components, particularly gear box housings, electrification devices/components, suspension arms and rear axle, are prime examples of driveline applications where aluminium is a favored material.
The complete series of M5 milling cutters offers everything from first stage machining to super finishing - for optimized quality and cost per part.
M5 milling cutters for ISO N materials:
The M5Q90 cleans the surfaces of newly casted aluminium cylinder heads and engine blocks in one smooth operation, without burring. The milling tool performs reliably and provides a long tool life.
The M5R90 is the first choice for roughing to semi-finishing in shoulder milling operations of automotive aluminium components such as cylinder blocks, cylinder heads, transmission housings.
The M5B90 face milling concept offers a highly effective tool for super finishing cylinder heads, blocks, covers, and other components with wide cutting engagements. The M5B90 prevents uneven tool wear and leads to a much superior tool life, even at high feed rates.
The M5C90 concept is based on M5B90 and likewise offers smooth burr-free cutting process, scratches and breakages with indexable inserts in a stepped configuration. What sets the M5C90 face mills apart, is their extra row of roughing inserts positioned tangentially on the outer diameter.
The M5F90 is a dedicated face milling cutter for machining thin-walled aluminum components in a single operation but it can also be used for spot facing and operations with wide material engagements.
https://www.sandvik.coromant.com/gb/News/technical_articles/pages/machining-aluminium-for-lighter-and-better-recyclable-vehicles.aspx
DLC Coating Offers a Competitive Edge for Machining Aluminum
December 11, 2019 by Michael Byron
In response to our many customers in these sectors, we have added drills, cutting inserts and endmills coated with DLC (Diamond-Like Carbon) to our product line. DLC is a unique thin coating composed mainly of carbon that features a high level of hardness, superior friction/wear properties and excellent adhesion resistance.
While working with aluminum creates some machining challenges, the positive properties of the material offset some of these difficulties.
https://sumicarbide.com/dlc-coating-offers-a-competitive-edge-for-machining-aluminum/
Case Studies of benefits of Sandvik Milling Tools for Aluminum
HOW TO OPTIMIZE ALUMINUM MACHINING IN THE AUTOMOTIVE INDUSTRY
Brought To You By Sandvik Coromant | Posted Apr 25, 2019
Application: Using M5C90 in a customer case trial involving a brake system body valve made from AlSi12Cu1. Featuring an outer diameter array of 10 carbide inserts and an inner diameter of four inserts (plus one wiper insert), the tool is being deployed at a spindle speed of 8000 RPM, a cutting speed of 4021 m/min. (13,192 ft./min.) and a feed of 0.25 mm/tooth (0.009 in./tooth). In addition, axial depth of cut is 2 mm (0.078 in.) with a radial depth of cut of 140 mm (5.51 in.), producing a metal removal rate of 5600 cm3/min. (342 in.3/min.). Total tool life is yet to be determined. The same tool is still within the machine after 18 months of service.
Impressive time savings are possible, as seen in a customer case trial that involved the face milling of an aluminum (high Si content) cylinder head. Here, the use of M5F90 against a special PCD cutter manufactured by a competitor, not only saw a 150% cycle time saving, but eliminated burr generation. Cutting data included: 15,915 RPM spindle speed; 2000 m/min. (6562 ft./min.) cutting speed; a feed rate of 0.16 mm/tooth (0.006 in./tooth); and 1.5 mm (0.06 in.) depth of cut.
In a further M5F90 example, cycle time reductions of 44% were achieved on an aluminum chain case in comparison with using a competitor’s 63 mm (2.48 in.) diameter indexable cutter featuring six PCD inserts. What’s more, the solution eliminated a previously required brush deburring operation.
Pitched against a competitor’s adjustable cutter with cartridges, the M610 achieved a tool life improvement of 833%, completing more than 4000 parts, in comparison with the competitor cutter’s 480. Moreover, the M610 performed at 10 times the speed. Cutting data for the 15-insert M610 included: 3000 m/min. (9843 ft./min.) cutting speed; a feed speed of 5720 mm/min. (225 in./min.); a spindle speed of 3820 RPM; a feed rate of 0.15 mm/tooth (0.006 in./tooth); and a depth of cut on aluminum of 0.5 mm (0.02 in.) and on cast iron of 0.05 mm (0.002 in.).
Aluminum cylinder heads and blocks are among the components to benefit from the M5Q90. By way of example, the cubing operation on a cast-cylinder head would typically involve machining the camshaft face, inlet/outlet face and combustion face. In a customer case study, the rough face milling of cylinder heads cast from AS-9 aluminum alloy on a horizontal machining center produced highly impressive tool life results. At 3000 m/min. (9843 in./min.) cutting speed, feed per tooth of 0.2 mm (0.008 in.) and 2.0 mm (0.079 in.) axial depth of cut (fully engaged to 40 mm (1.57 in.), more than 10,000 components were completed.
Still more applications
https://www.mscdirect.com/betterMRO/metalworking/how-optimize-aluminum-machining-automotive-industry
Milling cutters for automotive aluminum machining
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18 March 2019
As easy as one-two-three? Milling aluminium intelligently
04.10.2017
https://www.etmm-online.com/as-easy-as-one-two-three-milling-aluminium-intelligently-a-658975/
Machining chapter - interesting
https://books.google.co.in/books?id=O7tCAgAAQBAJ&pg=PA105#v=onepage&q&f=false
Bibliography
https://www.makino.com/resources/content-library/case-studies
https://www.visionwide-tech.com/en/work_06.html
21 Nov 2020
First pub: 11 June 2020
