Aerospace Industry
Tools engineered for manufacturing aircraft parts from lightweight materials such as aluminum alloys, Al-Li alloys, fiber composites and composites.
TOOLS for aeorspace applicatiions
AVIATION INDUSTRY PLACES EXTREME DEMANDS ON TOOLS AND PROCESSES
Milling cutters and drills for the production of aerospace components
In aviation, components are subjected to particularly high loads. In conjunction with the extreme safety and quality requirements, an extremely demanding environment is created, characterised by highly complex components and a wide variety of very different materials (and combinations thereof).
The production of the wings and fuselage mainly requires the processing of aluminium alloys. Composite materials such as CFRP and GFRP are also used, as are composites of these materials.
In the production of the components, the most important thing is to deliver absolute and consistent quality. We offer precision tools adapted to your application for the best machining results in the milling of fibre plastics. The same applies to drilling and reaming operations, whether manual, on drilling units, robots or CNC machining centres.
We offer solutions for milling, drilling and reaming aerospace materials, for use on CNC machining centres, on robots or for manual use.
We would be pleased to advise you on the subject of tool solutions for aviation.
CFRP/GFRP, Honey-Comb, Aluminium, Titanium, Inconel
SPPW has been developing innovative machining solutions especially for aerospace materials for many years.
DRILLING OF TURBINE BLADES
SIRIUS 761310 (3xDC) is a high-performance drill specially designed for machining tough materials such as stainless steel, titanium or special Ni-/Co alloys.
The high proportion of alloying elements makes machining more difficult. High cutting speeds and feed rates are required for economical drilling. This results in high loads and high demands on the twist drills used.
The edge preparation at the drill tip and the special tip grinding protect the drill bit and make themselves noticeable through increased precision and service life. The conical outlet after the cutting edge and narrow guide chamfers reduce frictional heat and thus wear.
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Component: Turbine blade
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Machine: MAZAK
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Cooling: Emulsion, 20bar
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Drilling depth: 30mm, through hole
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Diameter: 10mm
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Material: Inconel 718
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Tool life: 0.9m (machining end)
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Cutting speed vc: 23 m/min
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Feed rate vc: 58 m/min
- Cutting speed +90%
- Tool life x10
- feed rate +600%
- Cost savings 81
TITANIUM ALLOYS
e.g. TiAl6V4 (Grade 5) have a very good heat resistance and a high resistance against crack formation and
are therefore difficult to machine.
-> Our titanium tools have as many cutting edges and as many
sharp cutting edges and are mostly coated for better wear protection.
Pure titanium: medium strength
Ti alloys: high-strength
very corrosion-resistant low weight embrittled at high temperatures
then loses its formability.
High reactivity with many media at high temperatures/pressure
Titanium also burns with pure nitrogen, which must be taken into account when machining for example.
are therefore difficult to machine.
-> Our titanium tools have as many cutting edges and as many
sharp cutting edges and are mostly coated for better wear protection.
Pure titanium: medium strength
Ti alloys: high-strength
very corrosion-resistant low weight embrittled at high temperatures
then loses its formability.
High reactivity with many media at high temperatures/pressure
Titanium also burns with pure nitrogen, which must be taken into account when machining for example.
CFRP - "CARBON"
Carbon fibre (reinforced) plastic, consists of the C-fibre and the plastic matrix, mostly epoxy resin.
The properties of matrix and fiber complement each other. Machining by breaking the fibres. Heat is a problem because the matrix can degenerate. There is also a risk that CFRP will delaminate.
-> SPPW CFRP milling cutters have many cutting edges with chip breakers and are Dia.HC or diamond coated.
Cutters with alternating spiral direction avoid delamination.
The properties of matrix and fiber complement each other. Machining by breaking the fibres. Heat is a problem because the matrix can degenerate. There is also a risk that CFRP will delaminate.
-> SPPW CFRP milling cutters have many cutting edges with chip breakers and are Dia.HC or diamond coated.
Cutters with alternating spiral direction avoid delamination.
ALUMINIUM
Aluminium alloys (Mg, Si, Cu, Zn)
are very different in their machinability. For example, Al6061 is difficult to machine while Al7075 (AlZnMgCu1.5) is easy to machine.
Depending on the alloy, microstructural changes may occur during storage which cause changes in strength.
-> SPPW aluminium milling cutters have large grooves for optimum chip removal and between 1 and 3 cutting edges.
The cutter surfaces are often polished and coated (Dia.HC, Alu.Cut, Z.Cut) to prevent weld build-up.
are very different in their machinability. For example, Al6061 is difficult to machine while Al7075 (AlZnMgCu1.5) is easy to machine.
Depending on the alloy, microstructural changes may occur during storage which cause changes in strength.
-> SPPW aluminium milling cutters have large grooves for optimum chip removal and between 1 and 3 cutting edges.
The cutter surfaces are often polished and coated (Dia.HC, Alu.Cut, Z.Cut) to prevent weld build-up.
HONEYCOMB (COMPOSITE)
Honeycomb composites (WV) are used to improve (or enable) the structural strength of large components with the aim of reducing weight compared to solid materials.
Common honeycomb composites are aluminium, glass-based or aramid-based fibre plastics. Special forms made of paper can be found as well as those based on titanium.
Machining with normal tools is not possible because the honeycombs are pressed down and cannot be cut. Remains of the honeycomb remain, which have to be removed by hand.
-> SPPW Honeycomb milling cutters, also known as choppers or hoggers, have an extremely large number of small, spiky blades that divide the honeycomb structure and then peel it off.
The cutters are partly combined with a peeling knife at the forehead.
Common honeycomb composites are aluminium, glass-based or aramid-based fibre plastics. Special forms made of paper can be found as well as those based on titanium.
Machining with normal tools is not possible because the honeycombs are pressed down and cannot be cut. Remains of the honeycomb remain, which have to be removed by hand.
-> SPPW Honeycomb milling cutters, also known as choppers or hoggers, have an extremely large number of small, spiky blades that divide the honeycomb structure and then peel it off.
The cutters are partly combined with a peeling knife at the forehead.
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