Machining of titanium alloys

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Dora Russell
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1 Machining of titanium alloys Core competence: Landing gears Parts of aircraft wings Fuselage of aircrafts

2 Titanium properties of titanium : high tensile strength to density ratio high corrosion resistance fatigue resistance high crack resistance ability to withstand high temperatures Top references: (6 machines) Ural Avia, Russia KNAAPO, Russia Hydromash, Russia Landing Gear, Goodrich, Canada kurim.cz Page 1

Key principles for machining of titanium alloys: Reduce the high coefficient of friction of titanium = as possible to reduce the temperature at the tip of the edge.

Use substrate of inserts of following characteristics: a high resistance to abrasive wear a high resistance to plastic deformation high resistance to diffusion wear a high strength substrate (in some

3 Key principles for machining of titanium alloys: Reduce the high coefficient of friction of titanium = as possible to reduce the temperature at the tip of the edge. Use a sharp cutting edge and a large positive rake angle. Use substrate of inserts of following characteristics: a high resistance to abrasive wear a high resistance to plastic deformation high resistance to diffusion wear a high strength substrate (in some cases uncoated cast metal substrate worked very well) Utilize lower cutting speeds and give priority to climb milling. It is important to ensure an adequate supply of coolant to the tool. Machines are therefore equipped with a powerful coolant pump. Compared to the standard version of machine is a demand for more powerful coolant filtration because of chips which are light and swirl. Strategy for titanium alloys big extensionlength application plung milling application face milling - axial : feed vf ax - radial : steps - radial : feed F rad - small cutting depth (approach angle < 30 ) - high feed per tooth f kurim.cz Page 2

Machines which were deliver for machining of titanium: Machine FSQ 100-OR/DEI FSQ 100-KR/DEI FSQ 100-OR/DEI FSQ 100-OR/DEI FSQ 100-OR/DEI FSQ 100-KR/DEI FFQ 125-VR/A8 A FFQ 125-VR/A8 A FFQ 125-VR/A6

KR/A4 FO (Q) 80 VR/2,6 End user OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia OAO

4 Machines which were deliver for machining of titanium: Machine FSQ 100-OR/DEI FSQ 100-KR/DEI FSQ 100-OR/DEI FSQ 100-OR/DEI FSQ 100-OR/DEI FSQ 100-KR/DEI FFQ 125-VR/A8 A FFQ 125-VR/A8 A FFQ 125-VR/A6 A FFQ 125-VR/A6 A FFQ 125-VR/A6 A FFQ 125-VR/A6 A FSQ 100-SR/A2 FSQ 100-OR/A3 FSQ 100-OR/A3 FSQ 100-OR/A3 FSQ 100-OR/A3 FSQ 100-SR/A3 FFQ A 100 KR/A4 FFQ A 100 KR/A4 FSQ 80 KR/A2 FSQ 80 KR/A3 FSQ 100 KR/A4 FO (Q) 80 VR/2,6 End user OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia OAO Korporacija Irkut, Irkutsk, Russia IAZ Irkutsk, Russia IAZ Irkutsk, Russia KNAAPO, Russia KNAAPO, Russia Ural Avia, Russia Landing Gear, Goodrich, Canada Detailed examples of machining of titanium: Customer:. Machine: FFQ 125 VR/A8-A Type: Machining centre with movable column Commissioning: Basic parameters: X = mm, Y = mm, Z = mm Power: 37 kw End user: Own production of airplanes kurim.cz Page 3

Technological process of machining Workpiece: Titanium forging 1 th position: roughing

roughing of pockets with addition 1mm for finishing (Final thickness of pocket walls is

(clamped on rough side) 3 th position: Finishing operations from one side Original

5 Technological process of machining Workpiece: Titanium forging 1 th position: roughing of pockets side (removal of the stress in the forging), Machining allowance 5-30mm roughing of pockets with addition 1mm for finishing (Final thickness of pocket walls is 5-7mm) 2 th position: Specularly same operations + finishing operations from one side (clamped on rough side) 3 th position: Finishing operations from one side Original weight of the titanium forging was 400 kg Weight after machining was only 105 kg kurim.cz Page 4

6 Tooling For the machining of titanium alloys is necessary to determine the correct selection of appropriate technology and tools. Corner milling cutter Copy Milling cutter Copy Milling cutter Milling cutter made from cemented carbide kurim.cz Page 5

7 Roughing operations Tool: Corner milling cutter Xtratec F4042 D63, Z=6, ADMT1606PDR-F56 WXP45 Roughing of pockets side Vc=40 m min-1, fz=0,1mm Service life of the edge inserts: apx. 70min kurim.cz Page 6

8 Roughing operations Tool: Copy milling cutter F2234 D52, Z=4, RDMT 1605MO-D57 WXM35 Roughing of bottom parts and sides of the pockets of workpiece: Vc=40 m min -1, fz=0,1mm Service life of the edge inserts : cca.90min kurim.cz Page 7

9 Finishing Tool: Copy Milling cutter F2231, D32, Z=2, RDMT1605MO-D57 WXM35 (prefinishing) RDGT1605MO-G85 WMG40 (finishing) Finishing of pockets Vc=80 m min -1, fz=0,1mm Service life of the edge inserts: cca min kurim.cz Page 8

10 Finishing Tool: Copy milling cutter F2139, D20, Z=1, P3204-D20 WMG40 Finishing of pockets Vc=80 m min -1, fz=0,07mm Service life of the edge inserts: cca.130min kurim.cz Page 9

11 Finishing Tool: Milling cutter made from cemented carbide F1704E, D20, Z=8, coated WXK15 Finishing of pockets side Vc=50 m min -1, fz=0,05mm Service life of the edge: cca min kurim.cz Page 10

2009 Basic parameters: X = 6 200 mm, Y =

12 Machining of landing gears Customer: VSMPO, Verchnaja Salda, Russia Machine: FFQ 125 VR/A6 Type: Machining centre with movable column Commissioning: Basic parameters: X = mm, Y = mm, Z = mm Automatically interchangeable milling heads Power: 37 kw End user: Own production kurim.cz Page 11

13 Machining of chord of airplane wing Customer: VSMPO, Verchnaja Salda, Russia Machine: FFQ 125 VR/A6 Type: Machining centre with movable column Commissioning: Basic parameters: X = mm, Y = mm, Z = mm Automatically interchangeable milling heads Power: 37 kw End user: Own production kurim.cz Page 12

Machining of landing gears Customer: Landing Gear, Goodrich, Canada

7.2009 Basic parameters: X = 2 600 mm, Y = 1 650 mm, Z = 825 mm,

pressure coolant: 100 bar (especially for machining of titanium alloys)

contouring were delivered to an important Canadian company at the end of

only 150 kg, which proves that the machine has fulfilled all the

14 Machining of landing gears Customer: Landing Gear, Goodrich, Canada Machine: FOQ 80 VR/2,6 Type: Ram type machining center Commissioning: Basic parameters: X = mm, Y = mm, Z = 825 mm, Automatically interchangeable milling heads Acceleration: 4 m/sec² High pressure coolant: 100 bar (especially for machining of titanium alloys) Power: 30 kw Two highly productive and dynamic CNC machine tools for contouring were delivered to an important Canadian company at the end of The technology was adjusted for landing gear machining for Boeing airplanes. Forging (original weight of 400 kg) weighted after the final processing only 150 kg, which proves that the machine has fulfilled all the prescribed customer requirements for high speed machining in the aerospace industry. Technology program provided by Tebis AG, Germany kurim.cz Page 13

High performance High acceleration of linear axes 4 m/s -2 Water cooled

three-step gearbox and spindle drive chain at spindle heads Interchangeable

working area Machining of titanium 5553 Material: Machine: Power: Titanium

Milling Test, Climb Milling, Wet Tool: F4042.B27.063.Z06.

15 High performance High acceleration of linear axes 4 m/s -2 Water cooled longitudinal X - axes ball screws and main motor Thermal stabilization of three-step gearbox and spindle drive chain at spindle heads Interchangeable spindle heads for special customer s technological applications Closed working area Machining of titanium 5553 Material: Machine: Power: Titanium 5553 β Structure FF(Q) 100A / 125A 28 kw, 1200 Nm Application: Shoulder Milling Test, Climb Milling, Wet Tool: F4042.B Z06.15, Ø 63 mm,z:6 V c : 25 m/min n: 126 min -1 f z :. 0,12 mm V f : 91 mm/min a e : 25 mm a p : 10 mm kurim.cz Page 14

TRADITION - RELIABILITY - INNOVATION more than 65 years of tradition of development, design, production and service of

solutions Gantry type machining centres Motor output: 30 100 kw Column to column distance: up to 9 100 mm Execution: fixed

28 70 kw Vertical working travel: up to 6 000 mm Execution: with shift-out working spindle (diameter 130 mm, length 800 mm)

mm) adapted for automatic interchangeable milling heads

16 TRADITION - RELIABILITY - INNOVATION more than 65 years of tradition of development, design, production and service of machine tools turn-key delivery of technology guaranteed performance with adjusted technology tailor-made customer s solutions Gantry type machining centres Motor output: kw Column to column distance: up to mm Execution: fixed table / movable table Optional: hydrostatic guideway Optional: movable cross-rail Floor type machining centres Motor output: kw Vertical working travel: up to mm Execution: with shift-out working spindle (diameter 130 mm, length 800 mm) or with automatic interchangeable milling heads New execution: with shift-out boring spindle (diameter 160 mm, length mm) adapted for automatic interchangeable milling heads Contacts TOS KUŘIM OS, a.s., Residence of company: Štefánikova 41/110, Brno, Production plant: Blanenská 257, Kuřim, Czech Republic, sales@tos-kurim.cz Page 15

Efficient Machining Solutions in Titanium Alloys. David J Wills

Efficient Machining Solutions in Titanium Alloys David J Wills Acknowledgement The following presentation is a result of collaboration of ATI s metallurgists, scientists and engineers in providing an effective