Machining of titanium alloys Core competence: Landing gears Parts of aircraft wings Fuselage of aircrafts
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 www.tos- 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 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 www.tos- 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 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: 15.12.2005 Basic parameters: X = 8 200 mm, Y = 1 500 mm, Z = 2 000 mm Power: 37 kw End user: Own production of airplanes www.tos- kurim.cz Page 3
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 www.tos- kurim.cz Page 4
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 www.tos- kurim.cz Page 5
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 www.tos- kurim.cz Page 6
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 www.tos- kurim.cz Page 7
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.80-120min www.tos- kurim.cz Page 8
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 www.tos- kurim.cz Page 9
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.90-120min www.tos- kurim.cz Page 10
Machining of landing gears Customer: VSMPO, Verchnaja Salda, Russia Machine: FFQ 125 VR/A6 Type: Machining centre with movable column Commissioning: 16.12.2009 Basic parameters: X = 6 200 mm, Y = 1 500 mm, Z = 2 000 mm Automatically interchangeable milling heads Power: 37 kw End user: Own production www.tos- kurim.cz Page 11
Machining of chord of airplane wing Customer: VSMPO, Verchnaja Salda, Russia Machine: FFQ 125 VR/A6 Type: Machining centre with movable column Commissioning: 16.12.2009 Basic parameters: X = 6 200 mm, Y = 1 500 mm, Z = 2 000 mm Automatically interchangeable milling heads Power: 37 kw End user: Own production www.tos- kurim.cz Page 12
Machining of landing gears Customer: Landing Gear, Goodrich, Canada Machine: FOQ 80 VR/2,6 Type: Ram type machining center Commissioning: 15.7.2009 Basic parameters: X = 2 600 mm, Y = 1 650 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 2008. 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 www.tos- kurim.cz Page 13
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.B27.063.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 www.tos- kurim.cz Page 14
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: 30 100 kw Column to column distance: up to 9 100 mm Execution: fixed table / movable table Optional: hydrostatic guideway Optional: movable cross-rail Floor type machining centres Motor output: 28 70 kw Vertical working travel: up to 6 000 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 1 000 mm) adapted for automatic interchangeable milling heads Contacts TOS KUŘIM OS, a.s., Residence of company: Štefánikova 41/110, 602 00 Brno, Production plant: Blanenská 257, 664 34 Kuřim, Czech Republic, E-mail: sales@tos-kurim.cz www.tos-kurim.cz www.tos-kurim.cz Page 15