Faster Titanium Milling.
Extended Tool Life.

Executive Summary

Makino's latest T-Series 5-axis horizontal machining centers with ADVANTiGE technologies enable manufacturers to dramatically increase the efficiency of their titanium machining operations with up to 4 times the productivity and tool life. In this "twisted channel" demo, you will witness the T4 perform a rough slotting operation in Ti 6-4 using an 80mm cutter with full 5-axis contouring. At 14 cubic inches per minute of metal removal, these capabilities offer significant reductions, if not full elimination, of semi-finishing passes to clean "terraces" or jagged edges traditionally left behind by multiple 3-axis passes. This means dramatic savings in cycle time and tooling costs, and ultimately a more competitive and profitable stance in the rapidly growing market for three-dimensional contoured titanium part production.

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Executive Summary

Simultaneous 5-axis roughing and contouring offers several advantages over conventional 3-axis machining techniques, such as faster processing, reduction of uneven cutting forces and improved tool life. Shown here in steel, for demonstration purposes only, without the visual interference of the high pressure, high flow coolant system normally operating during titanium milling. By creating a near net shape during the roughing process, this permits manufacturers to eliminate semi-finishing processes all together.

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Executive Summary

In this demonstration, Makino’s T2 5-axis horizontal machining center roughs out a conical shape from a solid square block of Ti-6-4 at 14.27 cubic inches per minute. The resulting conicity is held within 21 microns with profiles ranging from 0.0001 inch to 0.0011 inch, and finishes of 17 micro inches on the back, 18 micro inches around the cone, 13 micro inches on the top and 16 micro inches on the floor.

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Executive Summary

This video demonstration illustrates the rigidity of the T-Series’ HSK-A125 spindle using a 22 inch long, 1.42 inch diameter high-feed cutter to reach across a part and mill a pocket in Ti-6-4. The process was run at 354rpm with a federate of 31.4ipm and chip load of 0.3 inches per tooth. At an axial depth of 0.02 inch and radial depth of 1.42 inches, a metal removal rate of .92 cubic inches per minute was achieved. Tool life for this finishing process was over 250 minutes.

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Executive Summary

The ADVANTiGE Active Damping System provides stable cutting across the entire workzone, including the highest points of the Y-axis. This provides for increased metal removal without causing damage to the spindle or rapid tool wear.

This demonstration offers a look into how the Active Damping System works, showcasing its capabilities through a titanium heavy-hogging process. Minimal cutting noise and vibration are involved as the T4 hogs out 122 cubic inches per minute (400cc/min) of titanium.

This demonstration also displays the T4’s side-by-side work-setting station that allows operators to shuttle parts in and out simultaneously, ultimately offering quick pallet changes and resulting in far less non-cutting time.

Mark Larson, Titanium R&D Team Leader, Makino
Masayoshi Hirahata

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Executive Summary

DEMONSTRATION: Extended Tool Life with Makino’s ADVANTiGE Technologies
This demonstration showcases results from a tool life test application. This test is run on both a conventional machine tool and the Makino T4 using a 5/8-inch diameter end mill. Both tools are run at the same speed of 2,428 min-1 with a 0.3mm radial depth of cut and are analyzed under a digital microscope to compare tool wear.

Due to titanium’s unique material characteristics, titanium cutting tools are an expensive commodity in the machining process. The ability of Makino’s ADVANTiGE technology to significantly reduce tool wear is a major cost cutting feature for manufacturers of titanium parts.

Mark Larson, Titanium R&D Team Leader, Makino
Masayoshi Hirahata

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Executive Summary

Makino’s ADVANTiGE™ titanium machining technologies include advanced processes as well as equipment, enabling Makino T4 and T2 5-axis horizontal machining centers to achieve four times faster processing and four times longer tool life than conventional machining technologies.

This presentation provides details and video demonstrations of seven specific processes Makino has developed to maximize ADVANTiGE technologies: (1) Heavy hogging in applications such as full-slot cutting; (2) 5-axis roughing to reduce setups and cycle times; (3) one-shot wall finishing with solid, rigid tooling for machining at higher speeds and greater axial depths of cut; (4) 5-axis facing to maintain controlled curvature and produce smoother surfaces; (5) 6-axis agility to reduce fixturing and tooling costs, as well as increasing accuracy; (6) 5-axis long-reach tooling to reduce the need for angle heads, reduce cycle times and save on tool costs; and (8) processes to improve tool life by as much as nine times (in finishing processes) over conventional machining.

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Executive Summary

Makino’s new T2 5-axis machining center is engineered and built to dramatically increase titanium milling efficiency for today’s aerospace applications.

This presentation describes the key technologies behind the T2’s unique capabilities. These technologies include a high-torque, high-power spindle with a rigid and compact tilting spindle head; a rigid machine structure, an active damping system to suppress machine vibrations; and a high-pressure, high-volume, through-the-spindle coolant system for optimal cooling and chip evacuation. The presentation also reviews the T2’s VP control and thermal stabilizer systems for machining accuracy, plus its Collision Safe Guard and Autonomic Spindle technologies for avoiding costly collisions and accidents.

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Executive Summary

Two of the most common challenges to milling productivity are tool/workpiece chatter and tool wear. The challenge for process engineers is to select the proper machining parameters to minimize both chatter and tool wear for the most efficient production of accurate parts.

This presentation describes modeling/simulation processes that generate stability lobe diagrams to identify the most efficient spindle speeds and axial depths for specific applications and avoid costly, time-consuming trial-and-error adjustments to machining parameters. For titanium machining, where surface speed is limited by tool wear, stability lobe diagrams can be used to maximize spindle speeds, which can increase the chatter-free axial depth of cut to maximize productivity while preventing unnecessary tool wear.

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Executive Summary

The superior strength-to-weight ratios and corrosion resistance of titanium alloys have led to an increasing demand for titanium components in the aerospace and petroleum industries. But titanium’s strength, low thermal conductivity and high chemical reactivity also make it difficult to machine. Controlling cutting temperature is particularly critical to achieving high-performance titanium machining.

This presentation reviews the latest research into cutting temperatures conducted at the Global Titanium R&D Center at Makino in Mason. The research is aimed at a better understanding of heat generation in order to optimize cutting conditions and select efficient cooling strategies to achieve maximum productivity, tool life and finished surface quality.

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Executive Summary

Two key benefits of Makino’s ADVANTiGE™ titanium machining technologies are capabilities to improve the typical roughing process through 5-axis roughing—often to the point where the semi-finish process can be eliminated—and to improve the typical finishing process through 5-axis contouring.

This presentation describes the theory, practices and processes behind ADVANTiGE 5-axis roughing and contouring. It shows, through both simulations and live-action demonstrations of sample applications, how 5-axis roughing produces a near net shape faster than conventional roughing and semi-finishing, and how 5-axis contouring (including one-shot wall finishing, high-speed surface cutting, high-feed floor finishing and finishing with long-reach tooling) can be applied to titanium parts.

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Executive Summary

Makino Products Address the Unique Needs of the Titanium Market
This presentation details four machining options, in addition to the T-Series, that Makino offers to address the unique needs of the titanium market.

The “M” package for a/A series machining centers is ideal for aerospace and other hard metal applications and offers the M-spindle, an HSK-100, 50-taper, high torque spindle; rigid design; 3 point support bed; roller type LG and high thrust ball screws.

The second option is the D500 5-axis vertical machining center. With sustained dynamic accuracy, high-performance, high-thrust capacity DD motors, three spindle options and ease of automation, the D500 is also a good option for titanium, especially titanium turbo industry parts where full 5-axis machining is needed. It also offers rigid, robust castings that are designed to ensure thermal stability and accuracy.

Makino is also rethinking the EDM process, opening it up to traditional aerospace applications with the DUO43 wire EDM which offers the advantage of wire consumption savings and performance in speed cutting and the EDGE3 sinker EDM which boosts performance by up to 80 percent, offering much faster burn rates.

Dave Ward, Horizontal Product Manager, Makino

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Executive Summary

Tool selection in the machining of titanium is unlike that of standard material processing. Based on the part geometries and specifications of the machining center, new considerations should be taken into account in choosing the most efficient tools for the job. In this presentation, Kennametal looks at how to define efficient processing of titanium through a variety of case studies. By evaluating specific challenges, solutions and other background details, the presenter determines how manufacturers can gain a competitive edge in their titanium machining processes with a complete tooling solution set.

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Executive Summary

Highly efficient machining of titanium looks not just at the machine tool, but also machining conditions, such as tooling, tool paths, cutting speeds, depth of cut and temperatures in the cutting zone. In order to drive down costs, manufacturers must optimize all critical aspects of the cutting zone for greater productivity and extended tool life. This presentation discusses the collaboration of ATI’s metallurgists, scientists and engineers in providing an effective understanding, techniques and solutions for improving the machinability of titanium alloys. Through the data they collected, ATI examines all factors that impact the machinability of titanium, including machine tools, component material, machining conditions and the cutting-zone environment. Specific considerations are given to cutter geometries and how they influence conditions of metal removal and temperature.

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Executive Summary

In this presentation, Makino and guest experts participate in a candid panel discussion focused on the latest advancements of titanium machining and how their current research has resulted in longer tool-life and greater productivity.

Review the list of questions below and select a hyperlink to jump directly to panel responses:

1. What do you view as the most important aspect of machine tool design when it comes to process damping?
2. What is the best type of coolant to use when high-speed machining titanium?
3. What is the most efficient tool path for titanium milling? Shallow-depth, full-cutter width, or full-depth with small percentage of cutter width?
4. How do Makino machines and processes manage depth of radial cut (cutting temperatures/cutting forces) when cutting titanium?
5. How does the proliferation of unequal flute spacing in the tooling cutters affect frequency in the response model?
6. With both machine tool builders and cutting tool manufacturers moving technology forward, who’s ahead now?
7. Aircraft parts are creating new demands. Between machine builders and tool manufacturers, what is the near and long-term future?
8. What do you view as the final result of your cutting zone temperature research?
9. What is the current best practice for measuring cutting edge wear and chipping?
10. Do you know of any emerging technologies for edge wear or chipping measurement?
11. Can you speak more about the tool life monitoring system within Makino’s Pro 5 software?
12. What new materials is Kennametal working on that allows for operations at higher heats?
13. In the Kennametal presentation, what method did you use in the face mill, round bore demonstration?
14. What seems to be the biggest challenge(s) in the development of the machining processes to improve overall productivity?
15. What is the best machine construction for tools to perform at their peak levels?
16. Did you consider hydrostatic ways vs. air?
17. How much research has been done on the different variances of the tombstone design/performance?
18. What are some of the positives and negatives of using cryogenic as a cooling option?
19. What PSI do you believe makes the biggest change in the performance or longevity of tools used to cut titanium?

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Executive Summary

Makino is helping companies reduce part costs by offering tooling, processing and equipment improvements with machines such as its new T2 and T4 5-axis horizontal machining centers.

With the T-Series, tool life is increased and operating costs are lowered. With less tool inventory, you have lower tool replacement labor costs and better quality. Metal-removal rates are also increased, resulting in less machine time and lower operating costs. With that comes less capital investment, lower equipment maintenance costs, less manpower required to operate the machines, less work in process and increased part turnaround times.

This presentation details the primary methods for reducing part costs, including longer tool life and higher metal-removal rates. This presentation also offers productivity and cost per part comparisons for the T4 and demonstrates that by capitalizing on the advantages of higher metal-removal rates and additional tool life found in machines like the T4, companies can begin to see a significant impact on their bottom line and cost per part.

Mark Larson, Titanium R&D Team Leader, Makino

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Executive Summary

Makino’s T-Series Machining Centers with ADVANTiGE Technologies
Makino’s new T-series five-axis horizontal machining centers with ADVANTiGE™ technologies are built specifically for titanium aerospace parts such as edge frames, pylons and bulkheads as well as inconels, nickel based alloys and additional materials that are difficult to machine. These technologies can provide manufacturers with four times the productivity and double the tool life of conventional titanium machining operations.

In this presentation, Makino introduces the first machines of Makino's T-series, the T4 five-axis horizontal machining center, Makino’s flagship product for titanium machining, and the T2 five-axis horizontal machining center, which has the same DNA and technology of the T4 but in a much smaller package. This presentation highlights the many benefits associated with these two pallet-changing T-series machines, including increased productivity and tool life.

This presentation also provides a detailed look into the specifications for the machining centers which have X travels between two meters and 4.2 meters. It also takes a look at the machines’ unique features, including ADVANTiGE technologies; horizontal part orientation; high torque, high performance and compact built-in T-Series spindle; high speed and high torque rotary axes; rigid construction; thermal stabilizer; VP control; APC; large magazine ATCs; and high pressure high volume TSC.

Dave Ward, Horizontal Product Manager, Makino

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Executive Summary

Test Cuts Demonstrate Benefits of Makino’s ADVANTiGE Technology
This presentation provides several detailed part machining examples, including a pylon spar, edge frame and frame component, as well as various cutting techniques that are being used to make the T4 machining center even more productive. Each of the before and after part samples illustrate the ability of ADVANTiGE to provide four times the productivity and double the tool life in titanium machining.

Several high pressure, high volume coolants were tested on roughing, semi-finishing and finishing applications and are also demonstrated in this presentation. Tool wear and tool life are closely monitored and reported, ultimately showing the increase in tool life that Makino’s ADVANTiGE technology affords, an important component in reducing operational costs.

By breaking through these conventional limitations of low metal removal and limited tool life, Makino’s ADVANTiGE technology provides a degree of machining efficiency that no other Titanium technology has offered in the past.

Masayoshi Hirahata

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Executive Summary

Improved Cooling, Lubrication and Chip Evacuation in Titanium Parts with the ADVANTiGE High Pressure, High Flow Coolant System
The ADVANTiGE high pressure, high flow coolant system delivers large volumes of high pressure coolant directly to the cutting zone for increased chip evacuation from multi-flute tools. The coolant system includes overhead shower, spindle nozzle, and through-spindle coolant for improved cooling, lubrication and chip evacuation in titanium parts.

This presentation demonstrates the effects of poor chip evacuation when cutting titanium. By delivering coolant at 53 gallons per minute and 1000 psi, the ADVANTiGE’s high pressure, high volume through spindle coolant provides excellent chip-evacuation capabilities even at metal removal rates of 24.4 cubic inches per minute. This reduction in chip re-cutting is critical for extending tool life in titanium machining applications.

Shinichi Inoue

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Executive Summary

Deeper Cuts, Higher Metal Removal Rates and Reduced Tool Wear with ADVANTiGE Active Damping System
By adjusting frictional forces based on low frequency vibration sensing, the ADVANTiGE Active Damping System avoids chatter and cutter damage resulting from structural resonance in real time. This vibration suppression enables deeper cuts, higher metal removal rates and reduced tool wear.

This presentation describes in detail the principles of vibration damping and machine rigidity, including the four major components to Makino’s Active Damping System.

Additional examples in this presentation also show the significant differences between conventional cutting performances and those enhanced by Active Dampening.

Shinichi Inoue

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Executive Summary

Every manufacturer has different constraints and every part has different features that impact machining capabilities. To break through past limitations of low metal removal and limited tool life, Makino has developed ADVANTiGE, a series of five technologies designed for improved spindle performance, coolant delivery, vibration damping, machine rigidity and cutting strategies.

This presentation demonstrates the meaning of how ADVANTiGE technology achieves four times the productivity and double the tool life in titanium production. By examining typical and expected metal removal rates, cycle times and tool life for conventional machining centers, and then providing a brief series of sample parts machined on the Makino T4 five-axis horizontal machining center, Makino clearly conveys the benefits of ADVANTiGE technology.

Mark Larson, Titanium R&D Team Leader, Makino

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