EDAF SERIES

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

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

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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