a 09 02311 aerospace catalog

8/21/2019 A 09 02311 Aerospace Catalog

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SUSTAINABLE SOLUTIONSAerospace Manufacturing and Advanced Materials for a New Generatio


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From lightweight composite materials to exotic alloys, Kennametal is committedto reducing risks and costs in the manufacture of aerospace and defense programs.

We partner with our customers to implement standard and customized solutions

with minimum cost per part and high repeatability in mind.

Kennametal has unique capabilities and resources to cover the total manufacturing

equation from high-purity metals to automated deburring and finishing.

This catalog includes a selection of our best-in-class technologies and services used

by our customers to deliver up to 30% cost reduction and 60% cycle time reduction.

To learn more, contact your Kennametal Representative, Authorized Kennametal

Distributor, or visit www.kennametal.com .


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Table of Contents

Introduction ..........................................................................................................111

Technical Machining Guides ..........................................................................A1A55

High-Temperature Machining Guide ........................................................A2A17

Titanium Machining Guide ....................................................................A18A33

Composite Machining Guide .................................................................A34A55

Engineered Solutions .......................................................................................B1B9

Milling .............................................................................................................C1C249

Indexable Milling ...................................................................................C2C194

Solid End Milling ...............................................................................C196C249

Holemaking .....................................................................................................D1D48

Turning ............................................................................................................E1E243

General Turning .......................................................................................E1E91

Threading, Grooving, and Cut-Off .......................................................E93E243

Services and Support ........................................................................................F1F7

Index ...............................................................................................................G1G54


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2 www.kennametal.com

Environmental Sustainability: A Core ValueAt Kennametal, we are deeply committed to designing and manufacturing environmentally

responsible products that deliver high performance and proven value.

Best Practices in Productivity

As your trusted partner for optimized production,Kennametal offers customers a unique commitmentto research and development excellence, leading tocontinued delivery of highly innovative ways to enhanceyour productivity. Certification to established standardssupports the manufacturing of Kennametal productsto the highest Industry quality requirements.

Best Performance,Less Environmental Impact

With technology, we can do both. Kennametal helpscustomers focus on the root causes of unsustainablebehavior in highly complex manufacturing systems,while at the same time improve cost structure, quality,and performance. In addition to offering the latest inmetal cutting tools and technology, our AdvancedEngineering team will analyze your existing productionprocesses and help you to identify new methodsto improve overall performance.


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Kennametal Extrude Hone

Means Precision Finishing

The worlds leading provider of advancedmanufacturing processes that produce someof the highest quality engineered surfaces andedges on the planet, Kennametal Extrude Hone

offers a menu of technologies and equipment fordeburring, polishing, and producing controlledradii in aerospace parts.

Any surface that meets uid, fuel, and airowcan be improved through various proprietarytechnologies, including abrasive ow machining,

electrolytic machining, and thermal energymethods of machining.

By processing housings, impellers, and turbines,for example, performance can be dramaticallyimproved. Airow efficiency can be increased byas much as 5%. The superior surface finish alsoprovides increased strength and improved reliabilityfor reduced environmental impact.

Kennametal continues to lead the industry

with innovative modeling techniques, setting

the standards for customized coatings that are asefficient as they are environmentally responsible.


Aerospace TechnologiesAerospace component surfaces are one of the key

battlegrounds in environmentally friendly manufacturing.

Surface treatments not only improve appearance of

the part, but also enhance wear resistance, providecorrosion protection, and improve friction control.

These subtle manufacturing enhancements provide

big dividends in the form of fuel efficiency, reliability,

performance, and longer part life.


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CAPABILITIES

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Products

ISA offers the products listed below, but has thecapability to customize alloys for customer-requestedchemistry and particle specifications.

High-Purity Chrome

Sputtering Target Materials

Master Alloys

Coating Materials

International Specialty AlloysInternational Specialty Alloys (ISA) provide cost-effective

metal alloy and metal alloy powder solutions for the

aerospace, electronics, and high-performance industrial

markets. ISA offers a variety of different products and

services for high quality, customized solutions that meetcustomer-specific purity, chemistry, and particle size needs.

Analytical Laboratory

The National Aerospace and Defense ContractorsAccreditation Program (NADCAP) approved laboratoryis capable of analyzing chemistry and particle size ofcustomers current materials with rapid turnaround. Thetechnicians in the laboratory mainly analyze metals andores, but are also knowledgeable on other materials.

Services

ISAs services focus on the fundamental elementsof metal alloy and metal alloy powder products todevelop customized solutions. ISA is capable ofproducing products made to strict particle size andgeometry needs, as well as to meet the chemistry andpurity standards of specified materials. ISA is also able

to refine bulk metal and metal powders. Services Includ Custom Sizing Solutions

Hybriding/Dehybriding Services

Vacuum Induction Melting Services

Refining Services

Hot Isostatic Pressing (HIP)


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Aerospace IndustriesExpertise and Excellence: Your Complete Supplier for Tooling Solutions

When an industry moves at mach speed, it needsan innovative and integrated supply base. Kennametalenables leading aerospace manufacturers to reducecost and risk. We provide high-performance toolsthat global aviation customers need to competeeffectively in the manufacture of engines, airframes,landing gear, and instrumentation with components.

Tried and Trusted Partner

for Optimized ProductionKennametal has experience and expertise on aninternational level, highly developed engineeringskills, and a global sales network. Both now and

in the future, we continue to bring innovative, high-performance products to market even more quicklythanks to our research and development excellence.Certification to established standards supports themanufacturing of Kennametal products to the highestIndustry quality requirements.

Committed to Your RequirementsOne particular challenge is the complete machiningof workpieces with defined cutting edges. Kennametalis the ideal partner for providing solutions to a widevariety of tasks in this field.

Why Not Put Us to the TestOur customers define the tasks and goals our Globalteam of Specialists analyze customer needs (green field orexisting operations) and provide options to meet even themost challenging requirements. And you, too, can use theKennametal Groups expertise in the field of completemachining.


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Kennametal Konnect is our custom-crafted,

dynamic online sourcing, ordering, and order

management tool that features the industrys

best products, knowledge, and, ultimately,

power. To learn more and register online,

visit us at www.kennametal.com.

Access our website 24 hours a day, 7 days

a week. No need to carry a catalog when you

travel. Just go to www.kennametal.com

and youre there.

Looking for the latest updates on

tooling solutions? The measurements

and specifications for a series of high-

performance metalworking tools? Or do

you need to determine the right insert with

the best geometry and coating for a specific

workpiece material? Youll find this informatioand more on www.kennametal.com.

Our E-Catalog is driven by images,

and our products are broken out exactly

as they are in our trusted print catalogs.

Check price, availability, and place orders

instantly with E-Catalog. Even download

detailed CAD drawings at a product level.


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Components

Flap Track

Pylon

2. Engine Components and Accessories

Blades/Blisks Disks/Shafts/Hubs Casings

Aerospace Components

1. Structural Components

Spars/Skins/Ribs/Frames


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3. Landing Gear Components

Main Landing Gear Beam

Landing Gear Components


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EnginesMaterials

PagesP N S H

Indexable Milling

Dodeka C8C19

Dodeka High-Feed C20C23

KSWM KenFeed C24C34

Mill 1-10 C36C64

Mill 1-14

C66C88KSSM C96C112

KSRM C116C147

KSSZR Plunge Mill C148C167

KPIR- KSSR C168C187

KDNR C188C189

Access/Screw-On/Modular C190C194

Solid End Milling

HARVI II/HARVI I C197C217

High-End Performance End Mills C218C221

Holemaking

Solid Carbide Drills D5D35

Y-Tech Drills D5, D14D21

Modular Drills D38D39

Indexable Drills D44D45

Holefinishing/Reamers D47D48Fine Boring (ModBORE/Romicron) D47, D49

Turning

Beyond Inserts

Kendex Inserts E12E18

Kenloc Lock Pin Inserts E19E41

Screw-On Inserts E42E61

K-Lock E63,E86E88

Top Notch E64E81

V-Bottom Round Toolholders E82E85

Threading, Grooving, and Cut-Off

A2/A3 E100E119

VG Deep Grooving Ceramic E120E123

A4 E124E173

Top Notch E174E243

Air FrameMaterials

PagesP N S H

Indexable Milling

Dodeka C8C19


KSWM KenFeed C24C34

Mill 1-10 C36C64

Mill 1-14 C66C88

Mill 1 Max C89C95

KSSM C96C12

HARVI Helical C104, C108C112

KSRM C116C147


KIPR-KSSR C168C187

KDNR C188C189


Solid End Milling



Aluminum End Mills/MaxiMet C222C233

Complete Component Solutions

(continued)


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Complete Component Solutio

Air Frame (continued)Materials

PagesP N S H

Holemaking





Holefinishing/Reamers D47D48Fine Boring (ModBORE/Romicron) D47, D49

Turning

Beyond Inserts


Kenloc Lock Pin Inserts E19E41

Screw-On Inserts E42E61

K-Lock E63, E86E88

Top Notch E64E81



A2/A3 E100E119


A4 E124E173

Top Notch E174E243

Components Materials PagesP N S H

Indexable Milling

Dodeka C8C19


KSWM KenFeed C24C34

Mill 1-10 C36C64

Mill 1-14 C66C88

Mill 1 Max C89C95

KSSM C96C12

HARVI Helical C104, C108C112

KSRM C116C147


KIPR- KSSR C168C187

KDNR C188C189


Solid End Milling



Holemaking





Holefinishing/Reamers D47D48

Fine Boring (ModBORE/Romicron) D47, D49

Turning

Beyond Inserts


Kenloc Lock Pin Inserts E19E41Screw-On Inserts E42E61

K-Lock E63, E86E88

Top Notch E64E81



A2/A3 E100E119


A4 E124E173

Top Notch E174E243


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Productivity in Aerospace Industry

The Challenges for Companies

The trends in Aerospace and Defense are clear: A relatively strong prospect for growth New, emerging materials used to produce

fuel-efficient aircrafts are difficult to machine The global expansion of the supply chain A shortage of talent in manufacturing

Today, corporations involved in the Aerospaceindustry are challenged in many ways. They mustbid aggressively on new programs, undertake hugeinvestments, understand and embrace a changingculture, and attempt to reduce time to market,all while minimizing the learning curve. This canbe especially difficult in an environment wherematerials and/or processes are new or evolving.

This section has been developed to share bestpractices in machining high-temp alloys, titanium,and composites. We hope to provide insight intostate-of-the-art technologies and principles so ourcustomers can machine these materials effectively.

The Challenges for Customers

The following example is a common challenge manyAerospace customers face: a Kennametal customerwas preparing to make a large and complex titanium

frame component, and was unsure of what processto follow.

It takes best practices and a lean mindset to drive

productivity in machining todays Aerospace materials.

Customers Question

Should they convert the existing gantry-stylemachines and make multiple parts slowly atthe same time, or should they invest in flexiblemanufacturing cells and make one part percenter much faster?

Kennametal Solution Profile

The customer consulted Kennametal to explorenew ideas and the possibility that investing in anew cell would provide greater and faster returnon investment. By applying the concepts explainedin this section, Kennametal co-designed a complete

solution that leveraged lean principles, the customerstechnical expertise, Kennametals experience, and themachine tool partners knowledge.

Kennametal team members spent several weeks on-site at the customers facility to gather and exchangeessential information. With full team approval, thesolution was designed and manufactured. Trial runswere performed at the machine tool builders facilitywith superb results, ensuring the viability of the conceptprior to implementation at the customers site. The solutionfor this challenge was outside of the box and leveragedevery piece of information contained in this section.

www.kennametal.com

Seethe Results


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Maximizing Productivity The Results

Table of Contents

High-Temperature Machining Guide................................................................ A2A17

Titanium Machining Guide ............................................................................. A18A33

Composite Machining Guide .......................................................................... A34A55

www.kennametal.com

Attribute Current Process New Process

Batch Size 5 1

Number of Machines and Spindles 4 and 20 3 and 3

Maximum Production Rate 1 part per day 2.5 parts per day

Total Flow Time 15.5 days 2 days

Work in Process 100 parts 7 parts

Maintenance Specialized General

Return on Assets Low High

Safety/Ergonomics High Risks Low Risks

Floor Space/Machine Footprint High Low


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High-Temperature Machining Guide

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MachiningGuides

HighTem

peratureMachiningGuide

High-Temperature MachiningSuperalloys, also known as heat-resistant superalloysor high-temperature alloys, are materials that can bemachined at temperatures exceeding 1000 F (540 C).No other alloy system has a better combination of high-temperature corrosion resistance, oxidation resistance,

and creep resistance. Because of these characteristics,superalloys are widely used in aircraft engine componentsand in industrial gas turbine components for powergeneration. They are also utilized in petrochemical,oil, and biomedical applications, specifically fortheir excellent corrosion resistance.

Today, fuel efficiency and reliability drive modern aircraftengine design. Engineers have long relied upon superalloys,such as INCONEL and Waspaloy, for their unique high-temperature and stress-resistance properties. Suchproperties are especially critical to the aerospace industry.

Modern aircraft engines are far more reliable than their

predecessors, and thanks to great strides in technology,it is now common to stay on wing for years. These enginesare also powerful and dependable enough that just two canpower large jetliners across entire oceans without concern.In addition to commercial applications, mission-criticaldefense operations increasingly rely upon the peakperformance and mission readiness the engines offer.

No material is perfect, however. Historically, one drawbackof superalloys has been their poor machinability. This iswhere Kennametal comes in.

Kennametal has decades of experience working with material

providers, OEMs, and parts manufacturers, resulting in anunmatched portfolio of standard and custom solutions. Weare proud to be the supplier of choice in superalloy toolingsolutions for most OEMs, and their subcontractors, aroundthe world.

We would like to share with you some of this knowledge,and are pleased to present the following guide to machiningthese materials. Topics covered range from understandingmetallurgical properties of superalloys to the besttechnologies for machining.


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MachiningGuides

HighTem


Nickel-Base Superalloys

Among the high-temperature alloys, nickel-basealloys are the most widely used. As a result, theyare often found in aerospace engine and powergeneration turbine components, as well as inpetrochemical, food processing, nuclear reactor,and pollution control equipment. Nickel-base alloyscan be strengthened by two methods: through solidsolution strengthening or by being hardened throughintermetallic compound precipitation in fcc matrix.

Alloys such as INCONEL 625 and Hastelloy Xare solid solution strengthened. These solid solutionhardened alloys may get additional strengthening fromcarbide precipitation. Alloys such as INCONEL 718,however, are precipitation strengthened. A third classof nickel-base superalloys, typified by MA-754,is strengthened by dispersion of inert particlessuch as yttria (Y2O3), and in some cases with

(gamma prime) precipitation (MA-6000E).

Nickel-base alloys are available in both cast andwrought forms. Highly alloyed compositions, suchas Rene 95, Udimet 720, and IN100, are produced bypowder metallurgy followed by forging. For the abovewrought alloys and for cast alloys (Rene 80 and Mar-M-247), the strengthening agent is precipitate. ForINCONEL 718, (gamma double prime) is the primarystrengthening agent. Alloys that contain niobium,titanium, and aluminum, such as INCONEL 725,are strengthened by both and precipitates.

Cobalt-Base Superalloys

Cobalt-base superalloys possess superior corrosionresistance at temperatures above 2000 F (1093 C)and find application in hotter sections of gas turbinesand combustor parts.

Available in cast or wrought iron form, cobalt-basesuperalloys are characterized by a solid solutionstrengthened (by iron, chromium, and tungsten),by an austenitic (face centered cubic or fcc) matrix,in which a small quantity of carbides (of titanium,tantalum, hafnium, and niobium) is precipitated.Thus, they rely on carbides, rather than precipitates,for strengthening, and they exhibit better weldability andthermal fatigue resistance than nickel-base alloys. Castalloys, such as Stellite 31, are used in the hot sections(blades and vanes) of gas turbines. Wrought alloys,such as Haynes 25, are produced as sheet, andare often used in combustor parts.

A4

Superalloy Classifications

High-temperature alloys are broadly classified into three groups: nickel-base,

cobalt-base, and iron-nickel-base alloys (titanium alloys are also included in this

category and are discussed in detail in the Titanium Machining Guide on pages D18D33.)


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High-Temperature Machining Gui

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Iron-Nickel-Base Superalloys

Iron-nickel-base superalloys are similar to wroughtaustenitic stainless steels, except for the addition of strengthening agent. They have the lowest elevatedtemperature strength among the three groups ofsuperalloys, and are generally used in the wroughtcondition in gas turbine disks and blades.

Most wrought alloys contain high levels of chromium,which provide corrosion resistance. They owe theirhigh-temperature strength to solid solution hardening(hardening produced by solute atoms dissolved inthe alloy matrix) or precipitation hardening (hardeningproduced by precipitate particles).

Alloys such as Haynes 556 and 19-9 DL are solidsolution strengthened with molybdenum, tungsten,titanium, and niobium. Alloys such as A286 and Incoloy909 are precipitation hardened. The most commonprecipitates are , (Ni3 [Al, Ti]) (e.g., A286), and ,

(Ni3Nb) (e.g., Incoloy 909).

Another group of iron-nickel-base alloys containshigh carbon content and is strengthened by carbides,nitrides, and solid solution strengthening. A group ofalloys, based on Fe-Ni-Co and strengthened by ,combines high strength with a low thermal expansion

coefficient (e.g., Incoloy 903, 907, and 909) and findsapplication in shafts, rings, and casings for gas turbines.

Metallurgy of Superalloys

High-temperature alloys derive their strength fromsolid solution hardening, gamma prime precipitationhardening, or oxide dispersion strengthening.

Metallurgy is controlled by adjustments in compositionas well as through processing, including the agingtreatment where the solution-annealed alloy is heateduntil one or more phases occur. The resulting austeniticmatrix combined with a wide variety of secondaryphases such as metal carbides (MC, M23C6, M7C3),, the ordered fcc strengthening phase (Ni3 [Al, Ti]),

or the (Ni3Nb) impart to the alloys their excellent

high-temperature strength.

Superalloy components are typically available in cast,wrought (forged), and sintered (powder metallurgy) formSome important characteristics to consider about eachform: Cast alloys have coarser grain sizes and exceptional

creep strength. Wrought alloys have more uniform and finer grain

sizes and possess higher tensile and fatigue strength Powder metallurgical processing enables production

of more complicated and near-net shapes.


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MachiningGuides

HighTem


Nickel-Base Superalloys

Properties: High-temperature creep resistance, corrosion resistance, and thermal shock resistance. Potential Source(s) of Strengthening:

Solid solution strengthening with Co, Cr, Fe, Mo, W, Ta, and Re (e.g., INCONEL 600 or INCONEL 625)

(Ni3 [Al, Ti]) precipitation hardening (e.g., INCONEL 718) Oxide-dispersion strengthening (e.g., IN-100 or Waspaloy) Applications: Aerospace engine components.

Cobalt-Base Superalloys

Properties: High-temperature creep resistance and superior corrosion resistance. Potential Source(s) of Strengthening: Primarily solid solution strengthening (Cr, Fe, and W),

but can have additional strengthening by carbides (Ti, Ta, Hf, and Nb). Applications: Hot sections (blades and vanes) of gas turbines and combustor parts.

Iron-Nickel-Base Superalloys Properties: Lowest elevated temperature strength among the superalloys, high corrosion resistance. Potential Source(s) of Strengthening:

Solid solution strengthening with Cr, Mo, and W (e.g., Discaloy) (Ni3 [Al, Ti]) precipitation hardening (e.g., A286)

Applications: Gas turbine disks and blades.

A6

Superalloy Classifications (continued)


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Machinability of Superalloys

As previously mentioned, superalloys generallyhave poor machinability. The very characteristicsthat provide superior high-temperature strength

also make them difficult to machine. Additionally,decreased cutting tool speeds can limit productivity.

The main challenges to machining superalloys include: The high strength of nickel-base superalloys at cutting

temperatures causes high cutting forces, generatesmore heat at the tool tip (compared to alloy steelmachining), and limits their speed capability.

The low thermal conductivity of these alloys transfersheat produced during machining to the tool,subsequently increasing tool tip temperaturesand causing excessive tool wear, which canlimit cutting speeds and reduce useful tool life.

The presence of hard, abrasive intermetalliccompounds and carbides in these alloyscauses severe abrasive wear on the tool tip.

Tool Life Modeling KC5010/KC5510 Machining Ti6Al4V

30

25

20

15

10

5

030 60 90 120 150 180 210 240

(100) (200) (300) (400) (500) (600) (700) (800)

Speed (m/min/[SFM])

ToolLife(min)

CNMG432UP .008 IPR/.050" docCNMG120408UP 0,2mm/rev/1,3mm doc

CNMG432MS .008 IPR/.030" docCNMG120408MS 0,2mm/rev/0,8mm doc

CNMG432MS .008 IPR/.050" docCNMG120408MS 0,2mm/rev/1,3mm doc

CNMG432UP .010 IPR/.100" docCNMG120408UP 0,25mm/rev/2,5mm doc

CNGG432FS .005 IPR/.010" docCNGG120408FS 0,13mm/rev/0,3mm doc

Finish Machining

.005 IPR/.010" doc0,13mm/rev/0,3mm doc

Light Machining

.008 IPR/.030" doc0,2mm rev/0,8mm doc

-FS-MS

-UP

-MS

-UP

All tests performed with flood coolant

KC5010 UP performs well in medium machining applications at 6090m/min (200300 SFM)KC5510 FS performs well in finishing applications at 137168m/min (450550 SFM)

The high capacity for work hardening in nickel-basealloys causes depth-of-cut notching on the tool,which can lead to burr formation on the workpiece.

The chip produced during machining is tough andcontinuous, therefore requiring acceptable chipcontrol geometry.

In addition to the challenges mentioned above,the metallurgical route by which the components areproduced also affects their machinability. These materialsare easier to machine in the solution annealed (soft) conditiothan in the heat-treated (hard) condition. Furthermore, undesimilar conditions of heat treatment, the iron-nickel-basesuperalloys are easier to machine than the nickel-baseor cobalt-base superalloys.

Finish machining is critical for aerospace componentsbecause the quality of the machined surface may influencethe useful life of the components. Great care is taken toensure that there is no metallurgical damage to thecomponent surface after the final finishing pass.

Medium Machining.008 IPR/.050" doc

0,2mm/rev/1,3mm doc

Roughing.010 IPR/.100" doc

0,25mm/rev/2,5mm doc


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MachiningGuides

HighTem


Machining Guidelines for Superalloys

When machining with CARBIDE tooling:

PVD coated carbide tools with positive rakes are suitable for finishing and medium machining. Reduces cutting forces and temperatures Minimizes part deflection

Always maintain high feed-rate and depth of cut. Minimizes hardening Use a generous quantity of coolant with carbide tools.

Reduces temperature build-up and rapid tool wear Utilize high-pressure coolant whenever possible. For rough cutting, T-landed ceramic inserts are recommended. With carbide inserts, use moderate cutting speeds.

Minimizes tool tip temperatures and encourages longer tool life Never allow tool to dwell.

Minimizes possibility of work hardening and subsequent problems in downstream process

When machining with CERAMIC tooling:

Higher cutting speeds of 6004000 SFM are possible with ceramic tools

(SiAlON and SiC whisker-reinforced Al2O3). There is no need for coolant. Depth-of-cut notching is more pronounced (versus carbides). When notching is severe (primarily in roughing cuts on forgings with scale), use higher lead angle.

Reduces tool pressure and work hardening and improves surface finish

When machining with PCBN tooling:

Use low-content PCBN grades for finishing and semi-finishing at low depth of cut, but optimizethe cutting conditions for each individual part, and pay close attention to surface condition.

Use sharp edge uncoated grades for better surface finishes and close tolerance. Use coated grades to increase tool life and productivity.

A8


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Machining Challenges for Superalloys

High-Temperature Alloys have a low thermal conductivity, meaning heatgenerated during machining is neither transferred to the chip nor theworkpiece, but is heavily concentrated in the cutting edge area.

These temperatures can be as high as 1100C to 1300C, and can causecrater wear and severe plastic deformation of the cutting tool edge.

Crater wear can, in turn, weaken the cutting edge, leading to catastrophicfailure. Crater wear resistance is an important tooling property requirementfor machining High-Temperature Alloys.

Plastic deformation, on the other hand, can blunt the edge, thereby increasingthe cutting forces. Retention of edge strength at elevated temperatures is alsoa very important tooling requirement while machining High-Temperature Alloys.

The chemical reactivity of these alloys facilitates formation of Built Up Edge(BUE) and coating delamination, which severely degrades the cutting tool leading to poor tool life. An ideal cutting tool should exhibit chemicalinertness under such extreme conditions.

The hard, abrasive intermetallic compounds in the microstructure causesevere abrasive wear to the tool tip.

The chip produced in this machining is tough and continuous, and requiressuperior chip breaker geometry.

Heat generated during machining can alter the alloy microstructure, potentiallyinducing residual stress that can degrade the fatigue life of the component.


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MachiningGuides

HighTem


Troubleshooting

High-Temperature Alloy Characteristics and Troubleshooting

Nickel-Base, Heat-Resistant Alloys (140475 HB) (48 HRC)

Astroloy, Hastelloy, B/C/C-276/X, INCONEL 601/617/625/700/706/718, IN100,Incoloy 901, MAR-M200, Nimonic, Rene 41, Udimet, Waspaloy, Monel

Material Characteristics

High forces at the cutting edge. High heat concentration in cutting area. High cutting speed may cause insert failure

by plastic deformation.

Relatively poor tool life. Small depths of cut are difficult. Rapid workhardening. Usually abrasive rather than hard.

Problem Solution

Depth-of-cut notch 1. Increase toolholder lead angle.2. Use tougher grades like KC5525 and KY4300 in -MS,

-MP, and -RP geometries or ceramic grade KY1540.3. Use a 0,63mm/.025" or greater depth of cut.4. Depth of cut should be greater than the workhardened layer

resulting from the previous cut (>0,12mm/.005").5. Program a ramp to vary depth of cut.6. Feed greater than 0,12mm/.005 IPR.7. Use strongest insert shape possible.8. When possible, use round inserts in carbide grade KC5510,

KC5010, or Kyon grades.9. Decrease depth to 1/7th of insert diameter for round inserts

(i.e.: 1,90mm/.075" max. depth for 12,7mm/1/2" IC RNG45).

Built-up edge 1. Increase speed.2. Use grades KY1540 or KY4300.

3. Use positive rake, sharp PVD coatedgrades KC5510 and KC5010.

4. Use flood coolant.

Chipping 1. Use MG-MS geometry in place of MG-FS or ..GP geometries.2. For interrupted cutting, maintain speed and decrease feed.3. Use a tougher grade like KC5525.

Torn workpiece 1. Increase speed and reduce feed rate.surface finish 2. Use a GG-FS or GT-HP geometry.

3. Apply KY1540 or KY2100.

Workpiece 1. Increase depth of cut.glazing 2. Increase feed rate and decrease speed.

3. Reduce insert nose radius size.

Depth-of-cut notch

Built-up edge

Chipping

A10

Torn workpiece surface finish


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High-Temperature Alloy Characteristics and Troubleshooting (continu

Cobalt-Base, Heat-Resistant Alloys (150425 HB) (45 HRC)

Wrought: AiResist 213, Haynes 25 (L605), Haynes 188, J-1570, StelliteCast: AiResist 13, Haynes 21, Mar-M302, Mar-M509, Nasa C0-W-Re, WI-52

Material Characteristics

High forces at the cutting edge. High heat concentration in cutting area. High cutting speed may cause insert failure

by plastic deformation. Cast material more difficult to machine than wrought.

Relatively poor tool life. Small depths of cut are difficult. Rapid workhardening. Usually abrasive rather than hard.

Troubleshooting

Problem Solution

Depth-of-cut notch

Built-up edge

Chipping

A


Depth-of-cut notch 1. Increase toolholder lead angle.2. Use a tougher carbide grade like KC5525

or ceramic grades KY1540, KY2100,or KY4300.3. Use a 0,63mm/.025" or greater depth of cut.4. Program a ramp to vary depth of cut.5. Feed greater than 0,12mm/.005 IPR.6. Use strongest insert shape possible.7. Depth-of-cut should be greater than the work-hardened

layer resulting from the previous cut (>0,12mm/.005").

Built-up edge 1. Increase speed.2. Use positive rake, sharp PVD coated

grades KC5510 and KC5010.3. Use ceramic grades KY1540 or KY4300.

Chipping 1. Use MG-MS geometry in place of GG-FS or ..GP.2. For interrupted cutting, maintain speed and decrease feed.

Torn workpiece 1. Increase speed.surface finish 2. Reduce feed rate.

3. Use a GG-FS, GT-HP, or GT-LF geometry.


3. Reduce insert nose radius size.


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MachiningGuides

HighTem


High-Temperature Alloy Characteristics and Troubleshooting (continued)

Iron-Based, Heat-Resistant Alloys (135320 HB) (34 HRC)

Wrought:A-286, Discaloy, Incoloy 801, N-155, 16-25-6, 19-9 DLCast: ASTM A297, A351, A608, A567

Material Characteristics Relatively poor tool life. Small depths of cut are difficult. Rapid workhardening. Usually abrasive rather than hard. Tough and stringy chips.

Common Tool Application Considerations

Problem Solution

Depth-of-cut notch 1. Increase toolholder lead angle.2. Use tougher grade like KC5525.

3. Use a 0,63mm/.025" or greater depth of cut.4. Feed greater than 0,12mm/.005 IPR.5. Increase coolant concentration.6. Vary depth of cut.7. Depth of cut should be greater than the workhardened

layer resulting from the previous cut (>0,12mm/.005").

Built-up edge 1. Increase speed.2. Use positive rake, sharp PVD coated

grades KC5510 or KC5010.3. Use ceramic grades KY1540 or KY4300.

Torn workpiece 1. Increase speed.surface finish 2. Reduce feed.

3. Increase coolant concentration.4. Use a GG-FS, GT-HP, or GT-LF geometry.


3. Reduce insert nose radius size.4. Use a GG-FS, GT-HP, or GT-LF geometry.5. Use PVD grade KC5510 as your first choice.

Depth-of-cut notch

Built-up edge

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Grades KC5510 and KC5525

Kennametals advanced PVD TiAIN coated carbidegrades KC5510 and KC5525, in high positive rakegeometries GG-FS and MG-MS, have overcome many

of the problems associated with machining heat-resistantalloys and titanium materials. These new products arerevolutionizing productivity in finishing and mediummachining of super alloys.

Cutting speeds as high as 122m/min / 400 SFM can beattained with finishing grade KC5510. Typically, speedscan be doubled over a conventional PVD product withno impact on tool life (see Figure 1).

Grade KC5510 is an advanced PVD-coated, fine-grainedtungsten carbide grade specifically engineered forthe productive yet demanding machining of high-temperature alloys. The fine-grain tungsten carbide(6% cobalt) substrate has excellent toughness anddeformation resistance. The advanced PVD coatingallows for metalcutting speeds double those ofconventional PVD-coated materials.

Grade KC5525 utilizes the same advanced PVD coatingas grade KC5510, combined with a fine-grain tungstencarbide (10% cobalt) substrate. The higher cobaltcontent provides added security in interrupted cuts whilethe fine grain tungsten maintains deformation resistance.

In conjunction with grades KC5510 and KC5525,Kennametal has engineered two chip control geometriesspecifically designed for machining superalloys. TheGG-FS geometry is precision ground for optimalperformance in finish cuts where low forces are requiredand dimensional control is critical. The MG-MS geometryis designed for medium to heavy cuts and is precisionmolded for added economy. Both geometries arehigh positive.

KennametalsCNGG-432FS KC5510Tool life: 26.5 minutes

CNGG-432 TiAlNTool life: 7.5 minutes

Figure 1: Comparison of a conventional TiAIN coated carbideinsert versus Kennametals advanced PVD grade(92m/min/300 SFM, 0,12mm/.005 IPR, 0,25mm/.010" doc,718 INCONEL 38 HRC)

NEW Cutting Tool Technologies

Kennametal developedthe KCS10 upgrade withdedicated MP geometry,a first choice for mediumand finishing applicationsin superalloys.

Features, Functions, and Benefits

A

MP geometry Superior chip conrol

Very positive geometry Minimized passive forces

Thin PVD coating Allows high-cutting speeds Extremely wear resistant

State-of-the-art dies Provide tighter tolerances

Chip control elementacross all edges

Chip control across all edges

Feature Function


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MachiningGuides

HighTem


GG-FS finishing sharp MG-MS medium sharp

Micrograph cross-section of the cutting edge. The higher cobalt content provides added securityin interrupted cuts while the fine-grain tungsten

maintains deformation resistance.

Finish Turning of INCONEL 718 (28 HRC)

CNGG-432FS (92m/min / 300 SFM0,12mm/.005 IPR.010 doc)

Figure 2: Kennametals advanced PVD grade KC5510 compared to best-in-class competitive grades.

relativetoollife

competitor 1 competitor 2 competitor 3 conventionalPVD

KC5510

NEW Cutting Tool Technologies (continued)

Grades KC5510 and KC5525

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Medium Machining of INCONEL

718

60

50

40

30

20

10

00 30 60 90 120 150 180

100 200 300 400 500 600

Figure 3: Tool life forINCONEL 718

Figure 5: Cubic inches ofmaterial removedcutting INCONEL 718

Figure 4: Helical cutting lengthfor INCONEL 718

toollife(min)

speed m/min (SFM)

KC5510 CNGG-432FSHelical Cutting Length

speed m/min (SFM)

KC5510 CNGG-432FSMetal Removed

Grades KC5510

In developing these products, Kennametal conducted extensive metalcutting tests internally and in conjunction with ourcustomers. In more than 100 tests, these new high-performance products outperformed the competition 95% of the time

Figures 35 document tool life in minutes, helical cutting length in meters/feet, and volume of metal removed in cu

3

/minfor grade KC5510 CNGG-432FS and CNMG-432MS. Materials machined were 152mm/6" diameter bars of INCONEL 718(39 HRC) and Ti-6Al-4V (30 HRC). Feed rates and depths of cut employed in these internal tests are indicated in the testresults. End-of-tool-life criteria used are 0,30mm/.012" flank-wear, nose wear, or depth of cut, and 0,10mm/.004" craterdepth. Use this metalcutting data as a benchmark for planning your machining operations to realize optimum economy.Calculate the helical cutting length based on the feed rate, workpiece diameter, and length of cuts. Determine theoptimum cutting speed from data in the following charts.

Finishing of INCONEL 718

Note that when machining INCONEL 718, grade KC5510 in CNGG432-FS geometry delivers tool life as high as ~50 min at60m/min / 200 SFM, 0,12mm/.005 IPR, and 0,12mm/.005" doc (Figure 3). This insert can be run even at 122m/min / 400 SFwith good tool life. For carbide tools, these speeds represent a 100%+ improvement in productivity over conventionalPVD-coated tools.

A

(continue

KC5510 CNGG-432FSTool Life

speed m/min (SFM)

IPR DOC.005" .005" inch0,12 0,12 metric

.005" .010" inch0,12 0,25 metric

.008" .010" inch0,20 0,25 metric


.005" .010" inch0,12 0,25 metric

.008" .010" inch0,20 0,25 metric


.005" .010" inch0,12 0,25 metric

.008" .010" inch0,20 0,25 metric

helicalcutting

length(ft)

helicalcuttinglength

cm

3/min

(in

3/min)


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MachiningGuides

HighTem


Whisker-shaped beta sialon grainsenhance fracture toughness.

Uniform alpha sialongrain size and compositionenhance hardness.

KY4300 is the Benchmark

Compared to KY1540, KY4300 can be expected toperform with lower wear levels and offer higher speedcapabilities. KY1540 has advantages in toughness and

depth-of-cut notch resistance, but the excellent wearresistance of KY4300 will produce better surface finishes,cut with lower forces, and enable higher speeds versusthe sialon grades.

KY1540 is Proven

In turning and milling applications. As a cost-effective replacement for expensive whisker

ceramic cutting tools.

In a broad range of high-temp alloy applications including: INCONEL products and other nickel-based materials. Stellites and other cobalt-based materials.

In a wide variety of machining conditions, includinginterrupted cuts and applications involving scale.

A16


718 (continued)

(continued)


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KY2100 Excellent Finisher

Extremely wear-resistant. Ideal for high-speed turning

and milling applications.

Well-suited for finishing cuts involvinga broad range of high-temperature alloys. Excellent for turning of hardened

high-temperature alloys (>48 HRC).

KY4300

Benchmark Excellent surface finish,lower cutting force,higher speeds.

Silicon carbide whiskersdeliver longer tool lifeand increased toughness.

KY1540 Proven

Long, consistent tool life. Excellent toughness and

depth-of-cut notch resistance. Performs in a wide variety of machining

conditions, including interrupted cutsand applications involving scale.

Feeds/Toughness

Speeds/WearResistance

A


718 (continued)

KY4300

KY1540KY2100


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Titanium MachiningTitanium is one of the fastest growing materials usedin aerospace applications. The prime rationale for designersto chose titanium in their designs is its relative low massfor a given strength level and its relative resistance tohigh temperature.

Titanium has long been used in aircraft engine front sectionsand will continue to be used there for the foreseeable future.In fact, due to its properties, titanium alloys are becomingmore prevalent than ever before in structural and landinggear components.

One drawback of these alloys is their poor machinability.Kennametal has decades of experience in working withmaterial providers (one of our divisions provides high-purityalloys for the industry), OEMs, and parts manufacturers.

Over the past few years, Kennametal has invested heavilyin Research & Development to understand how to better

machine titanium. Our research has led us to become theundisputed leader in titanium machining in the world,from engines to large components.

We would like to share some of this knowledge and arepleased to present the following guide to machine thesematerials, from understanding metallurgical propertiesto the best technologies to use.

Titanium Machining Guide

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MachiningGuides

TitaniumMachiningGuide

A18


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MachiningGuidesT

itaniumMachiningGuides

Machinability of Titanium Alloys

Machining of titanium alloys is as demandingas the cutting of other high-temperature materials.Titanium components are machined in the forged

condition and often require removal of up to 90%of the weight of the workpiece.

The high-chemical reactivity of titanium alloys causesthe chip to weld to the tool, leading to cratering andpremature tool failure. The low thermal conductivityof these materials does not allow the heat generatedduring machining to dissipate from the tool edge. Thiscauses high tool tip temperatures and excessive tooldeformation and wear.

Titanium alloys retain strength at high temperaturesand exhibit low thermal conductivity. This distinctiveproperty does not allow heat generated during machiningto dissipate from the tool edge, causing high tool tiptemperatures and excessive plastic deformation wear leading to higher cutting forces. The high work-hardeningtendency of titanium alloys can also contribute to thehigh cutting forces and temperatures that may lead

to depth-of-cut notching. In addition, the Chip-Toolcontact area is relatively small, resulting in large stressconcentration due to these higher cutting forces and

temperatures resulting in premature failure of thecutting tool.

The low Modulus of Elasticity (Youngs Modulus) ofthese materials causes greater workpiece spring backand deflection of thin-walled structures resulting in toolvibration, chatter and poor surface finish. Alpha () titaniumalloys (Ti5Al2.5Sn, Ti8Al1Mo1V, etc.) have relatively lowtensile strengths (T) and produce relatively lower cuttingforces in comparison to that generated during machiningof alpha-beta () alloys (Ti6Al4V) and even lower ascompared to beta () alloys (Ti10V2Fe3Al) and nearbeta () alloys (Ti5553).

A generous quantity of coolant with appropriateconcentration should be used to minimize high tool tiptemperatures and rapid tool wear. Positive-rake sharp toolswill reduce cutting forces and temperatures and minimizepart deflection.

Expert Application Advisor Titanium and Titanium Alloys

A20

Introducing Beyond BLAST, a revolutionary insert platform with

advanced coolant-application technology that makes cutting

more efficient and effective while extending tool life.

We took an entirely different approach to machining high-

temperature alloys. We determined that the most effectiveway to deliver coolant would be to channel it through the

insert, ensuring that it hits exactly where it does the most

good. That means more efficient coolant delivery at a

fraction of the cost of high-pressure coolant systems.

Case Study


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Titanium Machining Gui

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Alpha () Alloys

Pure titanium and titanium alloyed with stabilizers,such as tin and aluminum (e.g., Ti5Al2.5Sn), areclassified as alloys. They are non-heat treatable

and are generally weldable. They have low to mediumtensile strength, good notch toughness, and excellentmechanical properties at cryogenic temperatures.

Beta () Alloys

Beta () alloys contain transition metals, such as V, Nb, Taand Mo, that stabilize the phase. Examples of commerc alloys include Ti11.5Mo6Zr4.5Sn, Ti15V3Cr3Al3Sn, and

Ti5553. Beta alloys are readily heat-treatable, generallyweldable, and have high strengths. Excellent formabilitycan be expected in the solution treated condition. Howeve alloys are prone to ductile-brittle transition and thus areunsuitable for cryogenic applications. Beta alloys have agood combination of properties for sheet, heavy sections,fasteners, and spring applications.

Titanium Alloys

Pure titanium (Ti) undergoes a crystallographictransformation, from hexagonal close packed,hcp (alpha, ) to body-centered cubic, bcc (beta, )structure as its temperature is raised through 1620F /882C. Alloying elements, such as tin (Sn), whendissolved in titanium, do not change the transformationtemperature, but elements such as aluminum (Al) andoxygen (O) cause it to increase. Such elements are

called stabilizers. Elements that decrease thephase-transformation temperature are called stabilizers. They are generally transition metals.Commercial titanium alloys are thus classified as ,-, and . The - alloys may also include near and near alloys depending on their composition.

Alpha-Beta (-) Alloys

These alloys feature both and phases and containboth and stabilizers. The simplest and most popularalloy in this group is Ti6Al4V, which is primarily used inthe aerospace industry. Alloys in this category are easilyformable and exhibit high room-temperature strength and

moderate high-temperature strength. The properties ofthese alloys can be altered through heat treatment.

Beta alloy Ti3Al8V6Cr4Mo4Zr.Near -alloy Ti6Al2Sn4Zr2,Mo showing alpha grains and afine alpha-beta matrix structure.

Alpha-beta alloy Ti6Al4Vshowing primary alpha grains

and a fine alpha-betamatrix structure.

Microstructure of-alloy Ti5Al2.5Sn.

Metallurgy

A


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MachiningGuides


cold workingand heat effects

work-hardenedlayers

Titanium chips tendto adhere to the cutting

edges and will be re-cutif not evacuated fromedges. Plastic deformationsometimes occurs.

continuouslong chip

formation inaluminum

segmentalchip formationin titanium

Titanium and Titanium Alloys (110450 HB) (48 HRC)

Pure: Ti98.8, Ti99.9Alloyed: Ti5Al2.5Sn, Ti6Al4V, Ti4Al2Sn4Zr2Mo, Ti3Al8V6Cr4Mo4Zr,

Ti10V2Fe 3Al, Ti13V11Cr3Al, Ti5Al5Mo5V3Cr

Material Characteristics Relatively poor tool life, even at low cutting speeds. High chemical reactivity causes chips to gall and weld to cutting edges. Low thermal conductivity increases cutting temperatures. Usually produces abrasive, tough, and stringy chips. Take precautionary measures when machining a reactive (combustable) metal. Low elastic modulus easily causes deflection of workpiece. Easy work hardening.

A22

Titanium and Titanium Alloys Characteristics


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Built-up edge

Problem Solution

Depth-of-cut notch 1. Avoid built-up edge.2. Increase the tool lead angle.3. Use tougher grades like KC5525, KCU25, KCM25, or KCM35

in -UP, -MP, or -RP geometries for interrupted cutting or KC725M or KCPK30 in S edge geometries for Milling.

4. Maintain speed and decrease feed rate simultaneously.5. Use MG-MS geometry in place of GP.6. Ensure proper insert seating.7. Increase coolant concentration.8. Depth of cut should be greater than the work-hardened

layer resulting from the previous cut (>0,12mm/.005").9. Use strongest insert shape possible.10. Program a ramp to vary depth of cut.

Built-up edge 1. Maintain sharp or lightly honed cutting edges.Use ground periphery inserts and index often.

2. Use GG-FS or GT-LF geometry in PVD grades KC5510,

KC5010

, and KCU10

.3. Increase speed.4. Increase feed.5. Increase coolant concentration.

Torn workpiece 1. Increase feed and reduce speed.surface finish 2. Use positive rake, sharp PVD-coated grades KC5510 and KCU10.

3. Increase speed.4. Increase coolant concentration.

Workpiece 1. Increase depth of cut.glazing 2. Reduce nose radius.

3. Index insert to sharp edge.4. Do not dwell in the cut.

Depth-of-cut notch

A

Troubleshooting



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MachiningGuides


Goal Lowest Coefficient of Friction

A low coefficient of friction is developed by using propercoolant delivery. This results in lower temperature so theworkpiece doesnt get soft and tool life is extended. Under

pressure and direction, the coolant knocks chips off thecutting edges and provides anti-corrosive benefits formachine tool and work. There is a high correlationbetween the amount of coolant delivered and themetal removal rate.

For example, Kennametal drills are high-performance,solid carbide tools. To optimize their performance, theymust be adequately cooled. With the proper coolantflow, tool life and higher maximum effective cuttingspeeds can be reached. In Milling and Turning processes,applying coolant using our newest technology coolantdelivered at the cutting edge, through-the-tool coolant,or coolant nozzles to each insert is an optimal wayto increase tool life and maximize productivity. Coolantnozzles direct a concentrated stream of coolant to thecutting edge, providing multiple benefits. First, the cuttingedge and workpiece are kept as cool as possible. Second,the cutting edge and workpiece are also lubricated for aminimum coefficient of friction. Finally, the coolant streameffectively forces the cut chips away from the cutting

edge, thereby eliminating the possibility of recut chips.Provide a generous volume of coolant when machiningtitanium, and when applying drills and mills in a vertical

application to improve chip evacuation and increase tool life.It is important to use a high coolant concentration to providelubricity, which will aid in tool life, chip evacuation, and finersurface finishes. High-pressure coolant, either through thetool or through a line adjacent and parallel to the tool, shouldalways be considered for increased tool life and production.Do not use multi-coolant lines. Use one line with 100% of theflow capacity to evacuate the chips from the work area.

Coolant Considerations

Use synthetic or semi-synthetic at proper volume, pressure,and concentration. A 10% to 12% coolant concentration ismandatory. Through-coolant for spindle and tool can extendthe tool life by four times. An inducer ring is an option for

through-spindle flow.

Maximize flow to the cutting edges for best results. At least3 gal/min (13 liter/min) is recommended, and at least 500 psi(35 bar) is recommended for through-tool-flow.

The Importance of the Correct Use of Coolant

Marginally better coolant deliveryInadequate coolant delivery

Optimum coolant delivery usingKennametals Beyond BLAST technology

A24

Beyond BLAST

TM

delivers coolant directlyand precisely to the cutting edge

With effective thermal management,

higher speeds and reduced cycle times

can be achieved

Delivers many of the benefits of

high-pressure systems at low pressure

Beyond BLAST TMfor turning increases tool life by up to 200%

compared with conventional coolant delivery systems.

350%

300%

250%

200%

150%

100%

50%

0%

TestCond

ucted

at 100 ps

i

Coolant Pr

essure

SurfaceFe

et Per Min

ute

Beyond

BLAST

TM

System

Standard

Applicat

ion

300SFM

200SFM

Re

lativeToolLi fe

Beyond BLAST delivers coolant directly and

precisely to the cutting edge.

With effective thermal management, higher speeds

and reduced cycle time can be achieved.

Delivers many of the benefits of high-pressure

systems at low pressure.

Case Study


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Rigidity and Stability

Use gravity to your advantage. Horizontal spindles enable chips

to fall away from your work.

Horizontal fixturing necessitatesuse of tombstones or angle plates.

Therefore...

Keep work closest to strongest points of fixture. Keep work as close as possible to spindle/quill. High-pressure, high-volume, through-spindle coolant

delivery will increase tool life tremendously (>4x). Know the power curve of your machine. Ensure sufficient axis drive motors for power cuts. Every setup has a weak link find it! Rigidity will make or break your objectives:

Look for weak parts of machine structure andavoid moves that may compromise the rigidity.

Tool adaptation must fit the work an HSK63will not hold like an HSK100, nor will HSK or CVmatch KM adapters for rigidity.

Check for backlash in the machines spindle. Identify your drawbars pull-back force. Watch your adapter for fretting and premature

wear signs of overloading your cutting tool anddamaging your spindle and bearings over time.

Fixturing the Workpiece

If vertical spindles are employed,your fixturing is still an important aspect.

In either case, there may be directionsof work movement that are not secured.

Rigidity is paramount. Try to keep work close to the strongest points

of the fixture to help avoid the effects of harmonics.

Therefore...

Keep work low and secure. Keep work as close as possible to spindle/quill.

The productivity factor between typically used cuttingtools can easily be 4-to-1 in many cases. Older toolscan be replaced by todays tools if the entire systemis modified where needed and accounted for whereit is unalterable. Tool life can be increased by the samefactor simply by changing from flood to through-tool-coolant delivery and utilizing our newest technology,coolant delivered directly at the cutting edge.

Dont ask more of your machine than it can deliver.Most machines cannot constantly cut at a rate of30 cubic inches (492cc) per minute. There are manyusual failure or weak points in every system. Theyinclude, but are not limited to, drive axis motors, adapterinterface, a weak joint, torque available to the spindle,machine frame in one or more axes, or compound anglesrelevant to machine stability and system dampening.

Keep It Steady

T-slot toe clamp

Strongest points of fixture

A


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The Importance of a

Strong Spindle ConnectionIn the construction of todays modern aircraft, manycomponent materials are switching to high-strengthlighter materials like titanium to increase fuel efficiencies.To save time and money with this tougher-to-machine-

material, machinists are challenged to maximize metalremoval rates at low cutting speeds and considerablyhigher cutting forces. Machine tool builders must alsoprovide greater stiffness and damping in their spindles tominimize undesirable vibrations that deteriorate tool lifeand part quality.

Although all these advances add to greater productivity,the weakest point is often the spindle connection itself needing high torque and overcoming high-bendingapplications.

Kennametal's response to this traditionally weak pointhas been with our proven KM system and now we are

introducing the next generation KM4X System: thecombination of the KM4X Systems high clamping forceand interference level lead to a robust connection andextremely high stiffness and bending capacity forunmatched performance in titanium machining.

Overview of Existing Spindle Connection

To fulfill the increasing demand for high productivity, animportant element to be considered is the tool-spindleconnection. The interface must withstand high loads andyet maintain its rigidity. In most cases, it will determinehow much material can be removed on a given operationuntil the tool deflection is too high or the onset of chatter.

High-performance machining can be accomplishedwith the use of high feeds and depths of cut. With theadvances in cutting tools, there is a need for a spindleconnection that makes possible the best utilization ofthe available power.

Several different types of spindle connection have beendeveloped or optimized over the last few decades. The7/24 ISO taper became one of the most popular systemsin the market. It has been successfully used in manyapplications but its accuracy and high-speed limitationsprevent it from growing further. The recent combinationof face contact with 7/24 solid taper provides higheraccuracy in the Z-axis direction, but this also presents


www.kennametal.com

MachiningGuides


A26

KM4X The Next Generation

Spindle Connection System

Heavy duty, rigid configuration withevenly distributed clamping force.

Simple design enables front-loaded spindle designs. Balanced by design for high spindle speed capacity. Capable of performing in a wide range of operations

from low speed, high torque to high speed, low torque.

Fig. 1 The various spindle connections commerciallyavailable today: 7/24 ISO taper, KM (ISO TS),HSK, and PSC.

some disadvantages, namely the loss in stiffness at higherspeeds or high side loads. Most of these tools in the marketare solid and the spindles have relatively low clamping force.

In the early 80s Kennametal introduced the KV system,which was a shortened version of CAT V flange toolingwith a sold face contact system. In 1985, Kennametaland Krupp WIDIA initiated a joint program to furtherdevelop the concept of taper and face contact interfaceand a universal quick-change system, now known as KM.This was recently standardized as ISO 26622. The polygonaltaper-face connection known as PSC, now also standardizedas ISO 26623 and in the early 90s HSK system started beingemployed on machines in Europe and later became DIN69893 and then ISO 121.

Chart (Fig. 2) represents the load capacity of HSK, PSC, andKM4X. The shaded areas represent the typical requirementsfor heavy duty in various machining processes. KM4X is theonly system that can deliver torque and bending required toachieve high-performance machining. Some systems may

be able to transmit considerable amount of torque, but thecutting forces also generate bending moments that willexceed the interfaces limits before torque limits areexceeded.

KM4X 3-surface contact for improved stability andaccuracy. Optimized clamping force distributionand interference fit provides higher stiffness.


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www.kennametal.com A

Torque

Bending Moment

SK (V-flange)

SK-F (V-flange with face contact)

HSK

PSC

KM4X

Drilling

Face Millin

Turning

End Milling

Deep Borin

0 1000 2000 3000 4000 5000 6000

0.40

0.35

0.30

0.25

0.20

0.15

0.10

0.05

0.00

SK-F 50

SK50

SK60

HSK100A

HSK125A

KM4X100

KM4X125

Deflection[m]@150mm

Bending Moment [Nm]

150mm

F

Deflection

Fig. 2 Chart shows a comparison of Steep Taper withand without face contact, HSK and KM4X.

As an example, an indexablehelical cutter with 250mmprojection from spindle face,80mm in diameter generates4620 Nm of bending momentand less than 900 Nm of torque.

Choosing Whats RightWhen machining tough materials like titanium,cutting speeds are relatively low due to thermaleffects on cutting tools. In response, machine toolbuilders have improved stiffness and damping onspindles and machine structures over the years.Spindles have been designed with abundant torqueat low rotational speeds. Nevertheless, the spindleconnection remains the weak link in the system.

The spindle connection must provide torque andbending capacity compatible with the machine toolspecifications and the requirements for higher productivity.It becomes obvious that in end-milling applications wherethe projection lengths are typically greater, the limitingfactor is bending capacity of the spindle interface.

With more materials that are tougher to machine and requirconsiderably higher cutting forces from the machine tool,choosing wisely on the spindle interface to maximizecutting edge performance is the key to success.

The KM spindle connections greatly outperform theconventional 7/24 steep taper and its face taper contactderivative, HSK and PSC systems with their greater stiffnes

advantages to help minimize undesirable vibrations, gainingbest possible productivity from the machine tool. The KM4Xthe best large, heavy-duty spindle connection, where optimrigidity is necessary. It has superb balance between bendinand torsion capabilities from the machine tool.


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MachiningGuides


Dealing with High Cutting Tool Forces

Important Carbide

Material Properties

Strength to resist high cutting forces. Deformation resistance and high hardness

at temperatures encountered at cutting edge. Toughness to resist depth-of-cut notching.

Vickershardness

temperature C (F)

The TiAIN Advantage

0 200 400 600 800 1000

(392) (752) (1112) (1472) (1832)

3000

2500

2000

1500

1000

500

TiCN

TiAlN

TiN

Sharp edge

Lower tool pressure. Clean cutting action.

Weakest.

T-land edge

Strengthens edge;puts edge in compression.

Feed dependent.

Honed edge

Stronger than sharp.

sharp T-land hone

UsePosi

tiveRake

ToolGeo

metries!



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www.kennametal.com

Run jobs at significantly faster feeds and speeds than is achievable with other spindle interfaces. Unique use of clamping force and interference level increases clamping capability 2 to 3 times. You experience lower cost of ownership, increased throughput, and superior results.

The Latest Innovation in Spindle Interface Technology!

Dramatically increase your metal removal rates when

machining high-temperature alloys!

Visit www.kennametal.com or contact your local Authorized Kennametal Distributor.

KM4X

Load-Deflection chart

Deflection[mm]@

150mm

Bending Moment [Nm]


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MachiningGuides


Horsepower Calculations The 10x Factor

Titanium is 10x harder than aluminum ISO. In orderto machine titanium properly, its necessary to makecalculations based on the Brinell Hardness (HB) scale.To easily calculate the appropriate horsepower, theKennametal website provides engineering calculators.

The example shown on page A32 (Figure 4) represents aKennametal Face Milling application with high-shear cutters.Estimated machining conditions, force, torque, and powerare shown based on the HB. The following steps guide youthrough the procedure for utilizing the KMT calculator.

(continued)

Step 1:

Type in the following URL:http://www.kennametal.com/calculator/calculator_main.jhtmlSee Figure 1.

Or, from the Kennametal home page, click:

- Customer Support, then

- Metalworking, then

- Reference Tools, then

- Calculators


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(continued)

Figure 1

Figure 2

Figure 3

Step 2:

Select Face MillingSee Figure 2.

Step 3:

Make the appropriate measurement selection for Torque and Power(see Figure 3 on next page).In the following example (see page A32, Figure 4), inch has been chosen.


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MachiningGuides


(continued)

Example Explanation Figure 4

The tuning knobs that bring the predetermination of cutting forces closest to accuracy include the machinabilityfactor, a choice of tool conditions (new or worn edges), consideration of the machines drives, and most importantly,the materials ultimate tensile strength converted from hardness. The calculator is designed for a variety of applicationsand, in this example, face mills.

In this example of a real-life application, use of a .63 value for titanium would generate a horsepower value of 3.3,which is not close to the actual power required. The calculator accurately predicts the torque at the cutter which,

in this case, was 45% of the load meter given 740 lbfft. rating .45 x 740 = 0.333 lbf-ft. For the machineshorsepower rating of 47, the resulting horsepower required for this cut would be 21 hp. The calculator showsabout 12 hp and can be tuned by changing the p factor or machine efficiency factor.

NOTE: Inch values used for illustration purposes only, metric available on the website.

Keyinputvalue!

Figure 4


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Calculated Force, Torque, and Required Power

NOTE: Inch values used for illustration purposes only; metric available on the website.

(continued)

Tangentialcutting force, lbs

Torque at the cutter Machining power, hp

in. lbs. ft. lbs. at the center at the motor

1495.1 1868.9 155.7 6.3 7.0

Tangentialcutting force, N

Torque at the cutter Machining power, kW

N-m at the center at the motor

6650.5 211.1 4.7 5.2


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Composite Machining Guide


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mpositeMachiningGuide

Composite MachiningFor decades, the aircraft industry has utilized compositematerials in multiple applications, including flight surfacesand some internal cabin parts. Unfortunately, these materialsare unique to each design in their fiber layering techniques,resins, and curing processes, which creates great challenges

to consistency in manufacturing and assembly.

Composite materials are bonded together to form complexstructural sub-assemblies that must be either assembledtogether or attached to other structural components, suchas aluminum or titanium. This presents a unique set ofchallenges that requires radical new technologies.

One of the newest materials using carbon fiber and resinsis called CFRP (Carbon-Fiber Reinforced Polymer). Dueto attractive properties, such as weight-to-strength ratio,durability, and extreme corrosion resistance, CFRP is usedmostly in primary structure applications like aircraft hull

and wings.

Kennametal has years of experience working with materialsuppliers, machine tool providers, aircraft OEMs, and partsmanufacturers. We have invested substantially to betterunderstand how to machine CFRP/CFRP and CFRP/metalscombinations. Our research has led us to become a leader in

this field and has resulted in many exciting innovations, likeour diamond-coated drills and orbital holemaking solutions.

We would like to share some of this knowledge and arepleased to present the following guide to machiningcomposite materials from understanding theirproperties to selecting the best technologies.


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Characteristics of Composite Materials

Properties Compared to Common Engineering Materials

Overview Effect of Attributes on Mechanical and Machining Properties

High strength-to-weight ratio leads to widespread acceptance in structural aerospace components.

Corrosion resistance and radiolucent properties have made CFRP/carbon-fiber attractive in the medical industry.

CFRP/carbon-fiber reinforced polymers (particularly epoxy) have gained tremendous importance dueto their high strength-to-weight ratio.

Composite materials are generally composed of soft, tough matrix

with strong, stiff reinforcements. Fiber-reinforced polymers are

the broad class of composites usually targeted.

Fiber Reinforcements Carbon fiber/Graphite fiber

(high strength or high modulus) Glass fibers Ceramic fibers Polymer fibers (Kevlar, Polyethylene) Tungsten fibers

Polymer Matrix Epoxy Phenolic Polyimide Polyetheretherketone (PEEK)

Material Tensile Strength (MPa) Density (g/cm3)

Carbon-fiber epoxy 1,5003,000 1,52,0

Aluminum 600 2,7

Steel 6001,500 8,0

Attribute Properties Comments on Machining

Fiber High strength, high modulusAbrasiveness of fiberincreases with strength

Fiber length Small pieces of fiber delaminate easier

and present machining difficulties

Fiber diameterIncreasing diameter decreases

tensile strength

While tensile strength reduceswith diameter, cutting forces are

expected to increase

Matrix Toughness

% Volume of fibers Improves mechanical properties Adversely affects machinability

Fiber layout: Unidirectionalor fabric weave

Affects the degreeof anisotropy of properties

Delamination is usuallysevere in unidirectional tapes


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Types of Fiber Layout

Machining Challenges

Methods of Fabrication

Fiber can be laid in the matrix in severaldifferent configurations. Two commonexamples are:

Surface Quality

Delamination (separation of layers) Fiber pullout Uncut fibers Breakout

Rapid Tool Wear

Very rapid flank wear due to the abrasive natureof composites.

Most common method: Fiber-resin prepregs (tape),with one laid over top of another (each tape laid in oneor several directions) and one bag/vacuum molded toform a laminate.

Other methods include bulk resin impregnation,

compression molding, filament winding, pultrusion, etc.

Unidirectional tape Fabric weave

Tape-layered compositwith each tape havingunidirectional fibers indifferent directions.

Spalling

Breakout/delamination

Uncut fibers

Uncut resin

Spalling


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Standard End Milling

Compression End Milling

Tool Design for Composite Routing

The standard style end mills generate cutting forcesin only one direction. With a positive helix cutter,this will have the tendency to lift the workpiece

while causing damage to the top edge.

The compression-style router generates cutting forcesinto the top and bottom surfaces of the workpiece.

These forces stabilize the cut while eliminating damageto the workpiece edges.

Delamination-free bottom surface

Workpiece damage

Delamination

Fiber pullout

Force

Forces

Forces

Delamination-free top surface

Delamination-free bottom surface


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Aggressive ramping rates, high RPM capabilities, and a superiorsurface finish time after time.

Varying axial depth of cut, meeting the challenges of a widerange of applications.

No material breakout or burr formation upon entry or exitof the workpiece.

Ideal for applications utilizing Carbon-Fiber Reinforced Polymer (CFRP).

The Kennametal Mill 1-10 Indexable Milling Series Face Milling, up to 100% Engagement with PCD Inserts

Visit www.kennametal.com or contact your local Authorized Kennametal Distributor.

End or Face

Milling Mill 110

Choose the Mill 1-10 to mill 90 walls.


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Composite Milling Solutions

Kennametal has the right milling solutions designed for machining difficult CFRP (Carbon-Fiber ReinforcedPlastic) and non-ferrous components. Our diamond-coated (Grade KCN05) products provide excellent tool lifewhile producing smooth finishes with improved edge quality. Our unique geometries are free cutting, reducingheat generation and providing high quality machined surfaces.

Compression-Style Router Helix 25

Cutters are designed for high feed rates andproducing excellent quality edges on both sidesof the material. This up-cut down-cut geometrygenerates the forces into the workpiece, providingstable cutting conditions.

Burr-Style Routers Helix 15

Cutters were originally designed for trimmingfiberglass, but also are found to work in CFRP.Excellent temperature control while producinggood surface quality.

Down-Cut-Style Router Helix 25

Cutters are designed for surface work havinggreat ramping capabilities for producing pockets.Geometry designed to produce down forces to

eliminate surface delamination.

Ball-End-Style Routers Helix 30

Cutters are designed for slotting and profilingwhile providing excellent tool life.


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Features

Kennametal standard Through hole capability Plain shank Through coolant Helix angle 25

Application

Slotting and side milling Ramping capabilities Aerospace composites

and fiberglass

order number catalog number D1 D L Ap1 max Ap2 Z

4137446 CCNC0250J3AH .250 .250 2.500 0.750 .125 34137447 CCNC0250J3BH .250 .250 4.000 1.500 .125 34137448 CCNC0375A4AH* .375 .375 3.250 0.750 .125 44137449 CCNC0375A4BH* .375 .375 4.000 1.500 .125 44137279 CCNC0500A4AH* .500 .500 3.250 0.750 .125 44137280 CCNC0500A4BH* .500 .500 4.000 1.500 .125 4

order number catalog number D1 D L Ap1 max Ap2 Z4137452 CCNC0600A3AH 6,00 6,00 63 18 3,2 34137453 CCNC0600A3BH 6,00 6,00 100 36 3,2 34137281 CCNC1000A4AH* 10,00 10,00 83 18 3,2 44137282 CCNC1000A4BH* 10,00 10,00 100 36 3,2 44137443 CCNC1200A4AH* 12,00 12,00 83 18 3,2 44137444 CCNC1200A4BH* 12,00 12,00 100 36 3,2 4

Compression-Style Routers KCN0

Compression-Style KCN05 Inch

Compression-Style KCN05 Metric

* Through coolant available on 4-flute styles only.


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Features

Kennametal standard Plain shank Helix angle 15

Application

Slotting and side milling Ramping capabilities Aerospace composites

and fiberglass

order number catalog number D1 D L Ap1 max

4137459 CBDB0250JXAS .250 .250 2.500 .7504137460 CBDB0250JXBS .250 .250 4.000 1.5004137461 CBDB0375JXAS .375 .375 3.250 .7504137462 CBDB0375JXBS .375 .375 4.000 1.5004137473 CBDB0500JXAS .500 .500 3.250 .7504137474 CBDB0500JXBS .500 .500 4.000 1.500


4137475 CBDB0600AXAS 6,00 6,00 63 184137476 CBDB0600AXBS 6,00 6,00 100 364137477 CBDB1000AXAS 10,00 10,00 83 184137478 CBDB1000AXBS 10,00 10,00 100 364137479 CBDB1200AXAS 12,00 12,00 83 184137480 CBDB1200AXBS 12,00 12,00 100 36


4137493 CBDB0250JXAS .250 .250 2.500 .7504137481 CBDB0250JXBS .250 .250 4.000 1.5004137482 CBDB0375JXAS .375 .375 3.250 .7504137483 CBDB0375JXBS .375 .375 4.000 1.500

4137484 CBDB0500JXAS .500 .500 3.250 .7504137485 CBDB0500JXBS .500 .500 4.000 1.500


4137486 CBDB0600AXAS 6,00 6,00 63 184137487 CBDB0600AXBS 6,00 6,00 100 364137488 CBDB1000AXAS 10,00 10,00 83 184137489 CBDB1000AXBS 10,00 10,00 100 364137490 CBDB1200AXAS 12,00 12,00 83 184137491 CBDB1200AXBS 12,00 12,00 100 36

Burr-Style Routers End Cutting KCN05 and K600

Burr-Style KCN05 Inch

Burr-Style K600 Inch

Burr-Style KCN05 Metric

Burr-Style K600 Metric

(continued)


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Features Kennametal standard Plain shank Helix angle 25

Application Slotting and side milling Ramping capabilities Aerospace composites

and fiberglass

Additional Burr-styles point styles available upon request:

Non-End Cutting Drill Point Cutting End Mill End Cutting

order number catalog number D1 D L Ap1 max Z

4137719 CDDC0250J6AH .250 .250 2.500 .750 64137720 CDDC0250J6BH .250 .250 4.000 1.500 64137721 CDDC0375J6AH .375 .375 3.250 .750 64137722 CDDC0375J6BH .375 .375 4.000 1.500 64137733 CDDC0500J6AH .500 .500 3.250 .750 64137734 CDDC0500J6BH .500 .500 4.000 1.500 6


4137735 CCNC0600A3AH 6,00 6,00 63 18 64137736 CDDC0600A6BH 6,00 6,00 100 36 64137737 CDDC0375J6AH 10,00 10,00 83 18 64137738 CDDC0375J6BH 10,00 10,00 100 36 64137739 CDDC0500J6AH 12,00 12,00 83 18 64137740 CDDC0500J6BH 12,00 12,00 100 36 6

Down-Cut-Style Routers KCN0

Down-Cut-Style KCN05 Inch

Down-Cut-Style KCN05 Metric

(continued)

Down-Cut-Style Routers KCN05


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Features

Kennametal standard Plain shank Helix angle 30

Application

Slotting and side milling Aerospace composites

and fiberglass


4152648 CRBD0375J4AR .375 .375 3.250 .750 44152649 CRBD0500J4AR .500 .500 3.250 .750 4


4152650 CRBD1000A4AR 10,00 10,00 83 18 44152651 CRBD1200A4AR 12,00 12,00 83 18 4

Ball-End-Style KCN05 Inch

Ball-End-Style KCN05 Metric

Ball-End-Style Routers KCN05


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Mechanism of Damage During Drilling

Mechanism of Composite Machining

Tool Design for Composite Machining

Tool design should be developed with regardto the failure modes observed. Developmentcan be divided into two streams:

1. Geometry

Positive geometry to minimize stressesthat can cause delamination.

Sharp geometry to cut fibers with localized,induced strain.

Chip evacuation not essential, but dust needsto be evacuated.

2. Material

Sufficient hardness to resist abrasion wear. Strength to support sharp geometries.

While the machining of ductile metals is based on shearingthe machining of composites involves several mechanism

Compression-induced fracture of fiber (buckling). Bending-induced fracture of fiber. Shearing, yielding, and cracking of the matrix. Interfacial debonding. Sub-surface damage.

Torque twisting action causingpeel-in effect on entry.

Thrust action of the drill causingbreakout and delamination.

Tool

Composite

High-speed camera capture of breakout/delaminationwhen hand-drilling in CFRP. Look closely for the

extent of delamination prior to drill exit.


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71.17/16

66.72/15

62.28/14

57.83/13

53.38/12

48.93/11

44.48/10

2 7 12 17 22 27 32 37 42 47 52 57 62 67 72 77 82 87 92 97 102 107

3,05/0.12"

2,54/0.1"

2,03/0.08"

1,52/0.06"

1,02/0.04"

0,51/0.02"

0

a 09 02311 aerospace catalog

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