RESEARCH & DEVELOPMENT

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

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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