SUPER ALLOYS & STAINLESS STEEL ENGINEERED SOLUTIONS

Transcription

1 SUPER ALLOYS & STAINLESS STEEL ENGINEERED SOLUTIONS

2 SUPER ALLOYS & STAINLESS STEELS Energy Oil & Gas Automotive Aviation Medical Cutting tools in industries such as aerospace, medical, oil & gas, are being used on materials such as titanium s and nickel alloys and stainless steels, which are termed difficult-to-machine materials. The properties that make these materials so sought after, is the high toughness, high strength to weight ratio and low thermal conductivity, which is exactly why they are difficult-to-machine and form into complex shapes. These super alloys inherit very poor machinability (refer table below), since most of the heat is absorbed by the cutting edge. This creates quite a challenge for the cutting tool producers. provides the solution through extra attention to the tools attributes to withstand the heat build-up, such as specially selected carbide grades, optimised geometries and the ideal PVD coatings. 2 ISO Material group Material Machinability Free Cutting 1% P Steels Low Carbon 7-8% Medium Carbon 55-65% High Carbon 5-6% Austenitic 4-5% M Stainless Steels Duplex 4-55% Precipitation hardening 5-65% Titanium Alloy % S Titaniums & Super Alloys Fe Based 25% Nickel Based 1% Cobalt Based 5-1%

3 TOOL FINDER S M Ti Ni VA Page Material Recommendation Ti based alloys Ni based alloys Stainless Steels (precipitating) 4 VHM 5 Flute R4/42 Ti 4 Universal VHM 6 Flute R4/42 Ti 4 VHM 5 Flute R4/42 Ni MILLING 6 Roughing HSSE-PM R-VA HR 1 Universal Harmony VHM R4/42 VA 1 Roughing R5/6/6 HR 1 Slotting R55/54/56 VA VHM DRILLING 12 xd VHM R VA-IK 12 5xd 1 & 5xd HSS-Co R4 VA 7 Blind R15 Ti 7 Through PM-HSSE L12 Ti TAPPING 9 Blind/ Through 14 Blind HSSE/PM R1 Ni R4 VA R45 VA R5 VA 14 Through VA GUN 14 Blind/ Through PM-HSSE Former Optimal Effective

4 MILLING TITANIUM Common Grade - Titanium Alloy, TiAl6V4 (T-A6V), Grade 5 s - compressor blades, discs, and rings for jet engines; airframe and space capsule components, pressure vessels, rocket engine cases, helicopter rotor hubs, fasteners, critical forgings requiring high strength-to-weight ratios. Machining - often a similar practice to austenitic stainless steels. Best results are usually achieved with slower speeds, heavy feeds, rigid tooling, and large amounts of non-chlorinated cutting fluid. The chip thickness is paramount when machining titanium, getting this right, will have the biggest effect on your productivity. A relatively increased fz (mm/tooth) and moderately slower Vc (m/min) when compared to machining general steels, provides the best MRR, whereas higher speeds and lighter feeds will lead to premature tool wear, shorter tool life and potential distortion or poor surface finish on the component. Ti Series provides the following ranges with the above in mind, to ensure the highest productivity and process reliability is achieved. Shank Material MILLING Universal/ Trochoidal E464 E465 E466 E467 12mm - 2mm Square End Corner Radius 5 R4/42 Ti VHM-Ultra AlNova DIN6527 L R4/42 5-Flute Ti Carbide Endmill E466 Series Results Material TiAl6V4 E Holder Collet Chuck (Big Dashowa) Size ø16 x 4 Corner Radius Cutting Speed Vc (m/min) 9 RPM 14 Feed Rate Vf (mm/min) 572 Feed fz (mm/tooth).8 ae (mm) 4 ap (mm) Life (m) MRR (cm /min) Competitor Higher Productivity Comparison Competitor Cutting Force (N) % Lower Cutting Force Cutting Force (N) Time (s) Time (s) Key: Y-Axis X-Axis Z-Axis

5 MILLING TITANIUM Shank Material MILLING High Productivity E468 E469 E47 E471 12mm - 2mm Square End Corner Radius 6 R4/42 Ti VHM-Ultra AlNova DIN6527 L R4/42 6-Flute Ti Carbide Endmill E47 Series Comparison Material Holder TiAl6V4 HSK6 Shrink Fit (IMER) Size ø2 x R1 ae (mm) 6 ap (mm) 26 Competitor A E Flute, Variable Helix Cutting Speed Vc (m/min) 8 8 RPM Feed Rate Vf (mm/min) Feed fz (mm/tooth).6.6 Life (metres) MRR (cm /min) Cutting Time (min) Last 25% Longer Competitor Edge Condition after 4 mins. Normal wear, ideal for regrinds Before After 5

6 MILLING TITANIUM Shank Material MILLING Roughing E251 Roughing DIN185 4/5/6 R VA-R SPM AlCrN (LONG) E252 DIN844L B Roughing E255 6mm - 2mm 1mm - 2mm Square End Corner Radius DIN844K DIN844K RVA-R 5 Flute SPM Roughing Endmill E255 Series Comparison 1 Results Material TiAl6V4 E Holder Collet Chuck (Big Dashowa) Size ø16 x R4 Cutting Speed Vc (m/min) 2 RPM 98 Feed Rate Vf (mm/min) 119 Feed fz (mm/tooth).6 ae (mm) 1 ap (mm) 2 Life (m) 2x Life! Competitor Comparison 2 Results Material TiAl6V4 Special Custom Make Holder Collet Chuck Size 1.75mm (1.1/4 ) Cutting Speed Vc (m/min) 2 Life (m) Longer Life! RPM 2 Feed Rate Vf (mm/min) 79 Feed fz (mm/tooth).57 ae (mm) 16 ap (mm) Competitor 8 6

7 TAPPING TITANIUM Chamfer Material T215 M - M1 DIN71 6HX T216 M12 - M2 /4 DIN76 Blind holes T788 MJ - MJ1 DIN71 4HX C R15 Ti PM-HSSCo TiCN T789 MJ12 - MJ2 /4 DIN76 TAPPING T79 T791 T152 1/4" to /8" UNJC 1/4" to /8" UNJF M - M1 BX DIN DIN71 6HX T15 M12 - M2 /4 DIN76 Through holes T784 T785 MJ - MJ1 4HX B L12 Ti PM-HSSCo TiCN DIN71 T786 T787 1/4" to /8" UNJC 1/4" to /8" UNJF BX DIN R15 Ti HSSE-PM Tap - T215 Series Designed for optimal performance in titanium alloys, which are generally difficult to cut due to the work hardening, low heat conductivity and strong alloying characteristics. Ti range of taps offers high process reliability due to the optimised micro-finish coating, its specific grade of powder metal HSS tool material, and the unique cutting geometry that enables highly efficient swarf ejection that provides consistent thread quality. Torque (Ncm)/Thrust (N) Kistler Torque reading - vc=5m/min Time (s) Competitor Torque (Ncm) Ti Torque (Ncm) Sutton Ti Edge condition after 2 holes 7

8 MILLING NI BASED ALLOYS Common Grade - Inconels, such as 625 & 718 are heat resistant/high temperature alloys, which has the highest resistance to temperature, corrosion, oxidation and creep than any other alloy system. s - aircraft engine/exhaust systems, gas turbine & biomedical components. Machining It is extremely heat resistant, higher than titanium. It is not only the high temperature resistance that makes them difficult-to-machine, but the high strength causes high cutting forces, generating greater heat, limiting the speeds, hence limiting the productivity available. In addition to this, reduced tool life can result from the excessive tool wear caused from the low thermal conductivity characteristics on Inconels. The challenge to control the swarf/chips is vital since they are generally tough/work harden chips and can lead to burr formation or poor surface finish on the workpiece. For best results, much slower cutting parameters are preferred when compare to machining titaniums. Ni range encompasses a geometry set, that looks to offer reinforced cutting edges and carefully selected coatings to resist the high cutting forces encountered. Shank Material MILLING Universal/ Tro choidal E472 E47 E474 E475 12mm - 2mm Square End Corner Radius 5 R4/42 Ti VHM-Ultra X.Ceed DIN6527 L R4/42 5-Flute Ni Carbide Endmill E474 Series Excellent solution for shoulder and finish milling application, particularly for fine surface finish requirements, due to the multi-flute design the cutting forces and loads are distributed over more cutting edges than the conventional 4 flute endmills, resulting longer tool life. Wear Comparison 5 Flute Ni Coming Soon! Material Holder Inconel 718 (45 HRC) ER Collet Chuck Size ø16 x R1 ae (mm) ap (mm) 28 Competitor Competitor 4 Flute VA E VA 4 Flute Cutting Speed Vc (m/min) RPM Feed Rate Vf (mm/min) Feed fz (mm/tooth).7.7

9 TAPPING NI BASED ALLOYS Chamfer Material T217 M - M1 DIN71 T218 M12 - M2 6HX /4 DIN76 TAPPING Blind & Through holes T792 T79 MJ - MJ1 4HX J12 - MJ2 C DIN71 R1 Ni PM-HSSCo TiCN /4 DIN76 T794 T795 1/4" to /8" UNJC BX DIN /4" to /8" UNJF R1 Ni HSSE-PM Tap T794 Series For nickel base alloys such as Inconel 718 & 725, rapid tool wear has always been the problem, due to the materials extremely difficult machinability characteristics. now offers a Ni range that overcomes these issues, due to its reinforced cutting geometry that efficiently deals with the short chips produced when tapping this material group, providing longer tap life and process reliability in nickel based alloys. Competitor edge condition after 1 holes - Edge Worn Chipped Ni edge condition after 1 holes - protected design Reinforced area for longer tool life Material Inconel 718 Holder ER Collet Chuck Size 1/4"-2 UNJC B ap (mm) 1 Ni Competitor Cutting Speed Vc (m/min) 2 2 RPM 1 1 Feed Rate Vf (mm/min) Comparison Torque (Ncm) /4" UNJC R1 Ni - Ni VC = 2 M/MIN Time (s) Ni Competitor 9

10 MILLING STAINLESS STEEL s - Stainless steel is notable for its corrosion resistance, and it is widely used in aerospace, medical, automotive and the food processing industries, among many other applications. Stainless steel can be used for almost any part of an aircraft, however, its use in mainstream aircraft is hindered by its excessive weight compared to other materials, such as aluminium. Some of its common applications are in the fabrication of exhaust collectors, stacks and manifolds, structural and machined parts, springs, castings, tie rods and control cables. Machining - The machining of this material has been somewhat difficult due to its toughness and high work hardening properties. Specific geometry and cutting parameters optimised for stainless steels are essential & will make light work for machining processes. has developed a large range of solutions for stainless steels over many years, with its product offer summarised in the following. Shank Material MILLING Universal/ Trochoidal Slotting E459 E46 E462 E46 E41 E411 mm - 2mm 6mm - 2mm mm - 2mm Square End Corner Radius Square End 4 R4/42 VA VHM-Ultra Helica DIN6527 L 4 R4/42 VA VHM-Ultra Helica DIN6527 L R55/54/56 VHM-Ultra Helica DIN6527 L Roughing E416 E417 6mm - 16mm Square End R5/6/6 HR VHM-Ultra Helica DIN6527 L 1

11 MILLING STAINLESS STEEL R4/42 VA Carbide Endmill E462 Series (with multiple corner radius sizes available per diameter!) These high performance range of endmills are designed with variable helix geometry that suppresses chatter. With built in corner protection feature as standard, allows outstanding performance in trochoidal and universal milling of difficult to machine applications. If helical plunging/ramping and side milling is required with one tool, then this is the ideal design. The endteeth geometry has high relief and chip space to enable an efficient process, without the need to drill a hole when milling cavities. Material AISI 4 / 1.41 / AS 4 Holder E Size Cutting Speed Vc (m/min) 12 RPM 185 Feed Rate Vf (mm/min) 828 Collet Chuck Feed fz (mm/tooth).65 ae (mm) 2.4 ap (mm) 18 ø16 x 4 Corner Radius Comparison Competitor 2 2 Cutting Force (N) 1-1 Less Vibration Cutting Force (N) Time (s) Key: Less Vibration -2 2 YN XN ZN Time (s) 11

12 DRILLING STAINLESS STEEL Shank Material DRILLING xd 5xD D56 D57 D58 D59 mm - 2mm mm - 2mm IK IK HE HE 2 R VA VHM-Ultra Helica DIN657 2 R VA VHM-Ultra Helica DIN657 R VA-IK Black Magic Carbide Drill D56 Series The ideal solution for high-quality/high-volume drilling of the latest materials found in the aerospace and oil & gas industries. Aimed specifically at stainless steels and titaniums, the Black Magic range features a Balzers Oerlikon Helica multi-layer AlCr-based PVD coating, optimised for high temperature materials. This performance study compares the tool wear between the Carbide VA Black Magic Drills and three leading European brand drills. The results clearly indicate the longer tool life of the drill. Machine Holder Haas VF2-SS Vertical Machining Centre Hydraulic Chuck Size (mm) 6.8 Material AISI 554/1.41/V2A/ x5crni17-i Cutting Speed Vc (m/min) 7 Feed f (mm/rev).18 ap (mm) 4 Wear Wear mm Number of Holes Competitor A Competitor B Competitor C Minimal Wear Life Hole 6 Wear =.15mm Competitor A Hole 6 Wear =.mm Number of Holes Longer Life Competitor B Hole Wear =.mm Competitor C Hole 2 Wear =.15mm Competitor A Competitor B Competitor C 12

13 DRILLING STAINLESS STEEL Shank Material DRILLING Stub Jobber D15 D169.5mm - 2mm 2mm - 2mm DIN185 A 2 ~DIN1897 R4 VA HSSCo TiAlN 2 ~DIN8 R4 VA HSS-Co Drill D15 Series With its excellent resistance to corrosion, stainless steels are a popular material used in various industries namely aerospace, medical, automotive and food processing industries. Drilling stainless steels has been somewhat difficult due to its toughness and high work hardening properties. Specific geometry and cutting parameters optimised for stainless steels will make light work for producing holes, however, often carbide drill options are not ideal if relatively low batch size of components are required and perhaps the clamping or machine rigidity is less than ideal. This is where the R4 VA drills have been specifically designed to meet the requirements and demands in this area of application, the R4 VA offers precise hole quality at a much lower cost than carbide drills. High Helix & Unique Flute Form 4 flute helix with unique radius flute form. Produces short chips, even in stainless steel and copper alloys, allowing for non-step drilling of to 4xd hole depths possible. Resulting in superior drill life and hole condition. Material SS4 SS4F Cutting Speed Vc (m/min) 2 Feed f (mm/rev) Lubrication 7% water soluble 7% water soluble Material: SS4 Ø8mm / depth 16mm Vc = 2m/min f =.15mm/rev Material: Cu Ø8mm / depth 5mm Vc = 4m/min f =.15mm/rev life comparison between R4 VA Drill and competitors drill, 5mm diameter & 15mm deep SS4 SS4F Competitor A Higher Productivity Competitor B 1

14 TAPPING STAINLESS STEEL Chamfer Material Blind/ Through holes T25 T26 M - M1 M12 - M16 6H C Former SPM TiAlN DIN2174 T21 M - M1 DIN71 R45 VA DH T22 M6 - M6 6H /4 HSSE TiCN DIN76 Spiral Flute T251 MF6 - MF14 DIN74 Blind holes T262 #2 to 1" UNC C /4 T264 T277 8 UN Series 1/4" to 1" UNF 2B 4 /4 R45 VA DH Spiral Flute HSSE TiCN DIN T285 G1/8 to ISO228 /4 DIN5156 G1 (BPSF) TAPPING Through holes T112 M - M1 T11 M6 - M 6H /4 DIN76 T161 T171 T177 MF6 - MF14 #6 to 1" UNC #1 to 1" UNF DIN71 DIN74 VA GUN B HSSE TiCN Spiral Point 2B /4 2B /4 DIN T182 G1/8 to ISO228 /4 DIN5156 G1 (BPSF) T25 M1.6 - M1 DIN71 T26 M12 - M 6HX DIN76 Blind holes T252 T695 T696 MF6 - MF2 #2 to 5/8" UNC #4 to 5/8" UNF 2BX C /4 R5 VA Spiral Flute PM-HSSE TiCN DIN74 DIN T52 G1/8 to ISO228 G1 (BPSF) DIN

15 TAPPING STAINLESS STEEL Chamfer Material T116 M2 - M1 DIN71 T117 M12 - M2 DIN76 TAPPING Through holes T16 T697 MF6 - MF2 #2 to 5/8" UNC B /4 VAPM GUN Spiral Point PM-HSSE TiCN DIN74 DIN T698 #4 to 5/8" UNF DIN T5 G1/8 to G1 (BPSF) DIN5156 R5 VA PM-HSS Spiral Flute Tap T25 Series Results Material SS16 T25 6 Size M6 Cutting Speed Vc (m/min) 1 RPM 5 ap (mm) Number of Threads Competitor *Other sizes available to order on request Special Taps Service understands the difficulty of manufacturing super alloys. Our Special Service enables us to meet your requirements and deliver superior performance in Titanium & high temperature alloys. With our state of the art CNC grinding equipment almost any profile can be achieved. Feel free to discuss these with our Tech team. All Thread Forms M, MJ, UNJC, UNJF, Screw Thread Insert (STI) Sizes M2-M, #2-1" 15

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