machining of titanium - m.koskela[machining of titanium] tos kuŘim - os - kurim. cz page 2 coolant...

Core competence:

Landing gears

Parts of aircraft wings

Fuselage of aircrafts

Machining of titanium alloys

MACHINING OF TITANIUM[ ] TOS KUŘIM - OS

w w w . t o s - k u r i m . c z

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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:

VSMPO Verchnaja Salda, Russia (6 machines)

Ural Avia, Russia KNAAPO, Russia Hydromash, Russia Landing Gear, Goodrich, Canada



Page 2

Strategy for titanium alloys big extensionlength

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.

- axial : feed vfax

- radial : steps

- radial : feed Frad

- small cutting depth (approach angle < 30°)

- high feed per tooth f

application plung milling application face milling



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Machine End user FSQ 100-OR/DEI VSMPO Verchnaja Salda, Russia FSQ 100-KR/DEI VSMPO Verchnaja Salda, Russia FSQ 100-OR/DEI VSMPO Verchnaja Salda, Russia FSQ 100-OR/DEI VSMPO Verchnaja Salda, Russia FSQ 100-OR/DEI VSMPO Verchnaja Salda, Russia FSQ 100-KR/DEI VSMPO Verchnaja Salda, Russia FFQ 125-VR/A8 A VSMPO Verchnaja Salda, Russia FFQ 125-VR/A8 A VSMPO Verchnaja Salda, Russia FFQ 125-VR/A6 A VSMPO Verchnaja Salda, Russia FFQ 125-VR/A6 A VSMPO Verchnaja Salda, Russia FFQ 125-VR/A6 A VSMPO Verchnaja Salda, Russia FFQ 125-VR/A6 A VSMPO Verchnaja Salda, Russia FSQ 100-SR/A2 OAO Korporacija Irkut, Irkutsk, Russia FSQ 100-OR/A3 OAO Korporacija Irkut, Irkutsk, Russia FSQ 100-OR/A3 OAO Korporacija Irkut, Irkutsk, Russia FSQ 100-OR/A3 OAO Korporacija Irkut, Irkutsk, Russia FSQ 100-OR/A3 OAO Korporacija Irkut, Irkutsk, Russia 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

OAO Korporacija Irkut, Irkutsk, Russia IAZ Irkutsk, Russia IAZ Irkutsk, Russia KNAAPO, Russia KNAAPO, Russia Ural Avia, Russia Landing Gear, Goodrich, Canada

Machines which were deliver for machining of titanium:

Customer:. VSMPO Verchnaja Salda, Russia

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

Detailed examples of machining of titanium:



Page 4

Technological process of machining Workpiece: Titanium forging

1th 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)

2th position:

Specularly same operations + finishing operations from one side

(clamped on rough side)

3th position:

Finishing operations from one side

Original weight of the titanium forging was 400 kg Weight after machining was only 105 kg



Page 5

Tooling

For the machining of titanium alloys is necessary to determine the correct selection of

appropriate technology and tools.

Copy Milling cutter

Copy Milling cutter

Milling cutter made from cemented carbide

Corner milling cutter



Page 6

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



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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



Page 8

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



Page 9

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



Page 10

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



Page 11

Machining of landing gears

Customer: VSMPO, Verchnaja Salda, Russia

Machine: FFQ 125 – VR/A6



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



Page 12

Machining of chord of airplane wing

Customer: VSMPO, Verchnaja Salda, Russia

Machine: FFQ 125 – VR/A6



Basic parameters: X = 6 200 mm, Y = 1 500 mm, Z = 2 000 mm


Power: 37 kW

End user: Own production



Page 13

Machining of landing gears

Technology program provided by Tebis AG, Germany

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.

Customer: Landing Gear, Goodrich, Canada

Machine: FOQ 80 VR/2,6

Type: Ram type machining center


Basic parameters: X = 2 600 mm, Y = 1 650 mm , Z = 825 mm,


Acceleration: 4 m/sec²

High pressure coolant: 100 bar (especially for machining of titanium alloys)

Power: 30 kW



Page 14

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

Material: Titanium 5553 – β Structure

Machine: FF(Q) 100A / 125A

Power: 28 kW, 1200 Nm

Application: Shoulder Milling Test, Climb Milling, Wet

Tool: F4042.B27.063.Z06.15, Ø 63 mm ,Z:6

Vc: 25 m/min

n: 126 min-1

fz: . 0,12 mm

Vf: 91 mm/min

ae: 25 mm

ap: 10 mm

Machining of titanium 5553



Page 15

TRADITION - RELIABILITY - INNOVATION

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: [email protected]

www.tos-kurim.cz

Contacts

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
http://www.tos-kurim.cz/

machining of titanium - m.koskela[machining of titanium] tos kuŘim - os - kurim. cz page 2 coolant...

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