Welcome to SME Webinar on “New cutting tool geometry for milling and drilling of CFRP and CFRP/Titanium Stack materials" Presenter: Peter Mueller-Hummel, PhD, BU Aerospace April 6, 2009
This Webinar will begin at 12:00 p.m. EST Please note: All participants are muted during the presentation to avoid background noise. We encourage participants to use the chat feature throughout the presentation. A question and answer period will be held at the end of the Webinar.
Sponsor: This Webinar is brought to you by the Composites Manufacturing Tech Group, which is part of SME’s Plastics, Composites & Coating Technical Community www.sme.org/compositesmfg
Optimized Cutting Tools for machining Composites
Competence in Composite MD-PS-AIR-0807-001-E-a
Optimized Cutting Tools for machining Composites
Content Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti -/Al Stacks Summary MD-PS-AIR-0807-077-E-a
Optimized Cutting Tools for machining Composites
Content Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti -/Al Stacks Summary MD-PS-AIR-0807-077-E-a
Optimized Cutting Tools for machining Composites
Content Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti -/Al Stacks Summary MD-PS-AIR-0807-077-E-a
Optimized Cutting Tools for machining Composites
Content Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti -/Al Stacks Summary MD-PS-AIR-0807-077-E-a
Optimized Cutting Tools for machining Composites
Content Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti -/Al Stacks Summary MD-PS-AIR-0807-077-E-a
References of MAPAL users for Aerospace Applications
MAPAL supports Worldwide
subsidiaries agencies
• Subsidiaries in 20 countries / More than 3,200 employees • Agencies in 30 countries
MD-PS-AIR-0807-002-E-a
MAPAL Group - Germany
MAPAL Dr.Kress KG Aalen – Headquarter
MAPAL Sinsheim
Reamers
ISOTools
MAPAL Pforzheim
MAPAL Vaihingen/Horrheim
PCD-Tools
MAPAL Altenstadt
MAPAL München
Solide Carbide
Diamond Grit tools
Competence in Composite MD-PS-AIR-0807-001-E-a
MAPAL Group - Europe
England: MAPAL Ltd. Rugby
Czech Republic: MAPAL CZ s.r.o. Prag
Ireland: MAPAL Agent Ireland Rainey @ Lisburn
Spain: MAPAL Spain -AYMA Ezkio Itsaso (Guipuzcoa)
France: MAPAL S.A.R.L. St. Etienne and Paris
Italy: MAPAL Italia S.R.L. Mailand
Austria: TCM International GmbH Graz
MAPAL Group – America
USA:
USA:
MAPAL Inc. Port Huron
Apache Aerospace, Inc. Mukilteo
Mexiko:
Brasilien:
MAPAL Frhenosa Monterrey
MAPAL Precision Tools Ltda. Ibirite MD-PS-KHE-0208-079-E-b
MAPAL Group Asia
Japan: MAPAL KK Tokyo
India: MAPAL India Private Ltd. Bangalore
Taiwan: MAPAL PTS Tainan
Singapur: MAPAL Asia TET Office Singapur
Korea: MAPAL HTT Co. Ltd. Kyunggi - Do
Australia: Valcor Ballarat Thailand: MAPAL Thailand / Bangkok
China: MAPAL China Shanghai
Malaysia: MAPAL Malaysia Selangor
Products and Processes Capable for metal and composite stacks
Solid Carbide & PCD Helical and Straight fluted Drills
Fine Boring Tools with Guide Pads
Generating Tools
Face Milling
Solid Carbide / Diamond Grit / PCD End Mills CVD-Diamond Coated
Reaming Tools
Competence in Composite
Adapter HSK - X
Setting Fixtures
Process Know-how in machining CFRP Metal - Technology Semi- finished metal
NC Programming
Machining
Quality Approval Know-how barrier
Composite - Technology Manufacturing of composite parts
MD-PS-AIR-0807-025-E-a
Conventional milling
Climb milling
MD-PS-AIR-0807-067-E-a
Strategy for Milling CFRP Conventional Machining / Climb Machining
Clim b Ma ch.
Ff
Process Limit
nal o i t ven n o C
f Pyrolysed Surface Glued Dusts
Integer Surface
Vf = 0.6 m/min vC=750 m/min
Vf = 8.5m/min
CFRP Granulates
vC = 230 m/min
HPC on Trimming CFRP Trimming with rotating tools – low speed high feed is recommended.
P = 15 KW M = 48 Nm n = 6.000 U/min
vf = 33 sfm
• • • •
High Performance Low Noise Continuous Wear Fail Save
Trimming of CFRP Tools and Cutting Conditions PCD - 4 Cutting Edges PCD - 3 Cutting Edges Solid Carbide – Router (2)
P = 15 KW M = 48 Nm n = 6,000 rpm
10
30
9
Feed Rate [sfm ] Feedrate (m/min) Feed [m/min]
258
Carbide
7
20
PCD
PCD
Performance
6
155 4
103 5
wet wet
2
dry dry
1 0 00 .25”
10 .5”
.75”20
1”
30
40 1.5”
50 2”
Thickness (mm) [mm] Thickness of Component
MD-PS-AIR-0807-136-E-a
Content Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti -/Al Stacks Summary
Process Know-how in Drilling CFRP Fibre volume fraction high low
1 Strand = 25.000 Fibre
crack
CFRP “chips”
VC = 230m/min Fz = 0,7 mm
Drilling of CFRP Avoiding of Delamination and Fibreoverhang L/D = Fibre Volume Ratio high
L
Small Lever
D
low Resin
1 Roving = 25.000 Fibres
Delamination
Large Lever
L
D
Process Know-how in Drilling CFRP ϑ max
ϑ max
Source D.Dornfeld L/D = high lever
L D
D
Recommended for Metal
Recommended for Composite
Drilling Reaming and Counter Sinking
Drilling of rivet holes in CFRP Quality and tool life requirements are very high. Machining rivet holes in CFRP-HT • • • • • •
Drilling Reaming and Counter Sink IT 7 tolerance Improvement in tool life: 150 800 holes No chatter marks at the counter hole No delamination at the exit No Fibre overhang
Ø ¼” vc = 280 sfm f = .002” vf = 1.4 sfm MD-PS-AIR-0807-032-E-a
Competence in Composite
Content Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti -Al Stacks Summary
Drilling CFK/Titan/Aluminium Requirements Tool geometry must consider: - Diameter has to be constant. - Low burr formation am Titan und Aluminium. - Prevent fibre overhang on CFRP. - Prevent delamination on CFRP. - Always being “fail safe” - Low cost per hole. - High tool live.
Dornfeld
Titan CFRP
Aluminium
Aluminium
CFRP
Titan Entrance Metal / Exit CFRP
Entrance CFRP / Exit Metal
Dornfeld: Strategies for Burr Minimization and leanability in Aerospace and Atomotive Manufacturing
Drilling of CFRP/Ti - Stack-ups PCD-tipped drills are best solution. Cutting Conditition Single D = .336“ vc = 98,4 sfm n = 1000 rpm f = .0001“
Specific D = .336“ vc = 98 / 147 sfm n = 1500 / 1000 rpm f = .0001“
Exit Titanium
Ø 1/4” – 5/8”
Entrance CFK
MQL is recommended in any case
MD-PS-AIR-0807-033-E-a
Drilling Titan Force measurement
Ø 9,5 – axial force – f=0,15mm
Force measurement Thrust Fz [N]
measured
Diameters
Ø 9,5 – axial force – f=0,35mm
Competence in Composite
calculate
Drilling of stack-ups Tests Results
Thick .31
∅ .37“
.31
.25“ .25“
.37“
Entrance
Results vc = 98 sfm n = 1000 rpm f = .0001“ MQL vc = 98 sfm n = 1000 rpm f = .0001“ MQL
Exit
good
Fibre Overlap
good
Small caps, sometimes
good
Fibre Overlap
good
Small caps, sometimes
good
Fibre Overlap
good
Small caps, sometimes
vc = 98 sfm n = 750 rpm f = .0001“ 1,5“
0.86“
.5“
Wet machining
Good: Bur under .008” or no delamination/fibre overhang
Machining From CFRP Side • Excellent hole entrance • sometimes caps
• 72 Holes in Boeing sample Material. •Tool performed still excellent.
Competence in Composite
Contend Capability in Composites - Worldwide Trimming of CFRP Drilling of CFRP Drilling of CFRP/Ti - Stacks Summary MD-PS-AIR-0807-077-E-a
Products and Processes Capable for metal and composite stacks
Solid Carbide & PCD Helical and Straight fluted Drills
Fine Boring Tools with Guide Pads
Generating Tools
Face Milling
Solid Carbide / Diamond Grit / PCD End Mills CVD-Diamond Coated
Reaming Tools
Competence in Composite
Adapter HSK - X
Setting Fixtures
For further Information please feel free to contact
Dr. Peter Mueller-Hummel Senior Manager BU Aerospace MAPAL Dr. Kress KG Obere Bahnstr. 13 – D-73431 Aalen Phone: +49 (0) 73 61 - 585-3381 Email:
[email protected] http://www.mapal.com
MD-PS-AIR-0807-081-E-a
MD-PS-AIR-0807-082-E-a
