PCD for machining challenging aviation components
Most of the components used for modern aircraft and helicopters consist of aluminium alloys or composite materials or combinations of these materials. This has to do with the prevention of material fatigue at simultaneous low weight. When machining aviation components, the main focus is on process reliability. PCD tools from MAPAL meet this requirement to a high degree and also have impressively long tool lives and produce the best machining results.
60 percent longer tool life when drilling composite materials
In aircraft construction, thousands of bores have to be drilled into composite components and material assemblies for riveted connections. Solid carbide drills with a diamond coating are usually used for this. However, these are unsuitable for special applications. The limits are to be pushed back even further, especially with extremely high demands on tool life, process reliability and quality of the bore.
MAPAL has developed a new PCD drill for machining composite materials such as CFRP (carbon fibre reinforced plastic) and multilayer composites made of aluminium and CFRP in assembly. The drill distinguishes itself through its continuous PCD cutting edge. Up to now tips made of solid carbide have mostly been used in the centre, only the sides were PCD-tipped. However, the interruption of the cutting edge caused instability at the transitions and the brazed gap tended to break out. MAPAL has eliminated this instability with the new tool.
The PCD cutter, polished on both sides, is inserted into the slotted tool body made of solid carbide. This makes the whole system particularly stable. The drill centres itself very well due to the tip angle of 115˚. The differential tip angle of 80° ensures a clean bore exit without delamination.
The drill is convincing during customer applications not just because of its high process reliability. A long tool life is an added bonus. In this case, holes for bolts are made in a helicopter component. The component consists of 50 mm thick CFRP. The tool used so far had reached the end of its service life after 50 bores. With higher cutting values and a significantly better quality of bore, the customer can drill over 80 bores at a diameter of 19 mm with the PCD drill from MAPAL - an increase of 60 percent compared to tools with only PCD tipped sides.
MAPAL has developed a new PCD drill for machining composite materials such as CFRP (carbon fibre reinforced plastic) and multilayer composites made of aluminium and CFRP in assembly. The drill distinguishes itself through its continuous PCD cutting edge. Up to now tips made of solid carbide have mostly been used in the centre, only the sides were PCD-tipped. However, the interruption of the cutting edge caused instability at the transitions and the brazed gap tended to break out. MAPAL has eliminated this instability with the new tool.
The PCD cutter, polished on both sides, is inserted into the slotted tool body made of solid carbide. This makes the whole system particularly stable. The drill centres itself very well due to the tip angle of 115˚. The differential tip angle of 80° ensures a clean bore exit without delamination.
The drill is convincing during customer applications not just because of its high process reliability. A long tool life is an added bonus. In this case, holes for bolts are made in a helicopter component. The component consists of 50 mm thick CFRP. The tool used so far had reached the end of its service life after 50 bores. With higher cutting values and a significantly better quality of bore, the customer can drill over 80 bores at a diameter of 19 mm with the PCD drill from MAPAL - an increase of 60 percent compared to tools with only PCD tipped sides.
ドライ加工用PCD粗加工用カッター
アルミニウム製の航空機の翼を加工する際に、既存の材料の大部分が加工によって除去されます。翼内のチャンバーやポケットの粗削り加工用に、マパールはOptiMill-SPM-Roughともにその性能が何度も実証されている超硬エンドミルを用意しています。しかしこのラフィングカッターは湿式加工にしか適していません。その理由は航空機の構造物に使用されるようなロングチップのアルミニウム合金のドライ加工の場合、ソリッドカーバイドツールでは限界に達します。すぐに構成刃先が形成され、ツールは過度の摩耗にさらされます。
翼のチャンバーやポケットがクーラントで満たされないように、PCD装備のミーリングカッターを備えたマパールに対応するドライ加工用ツールに対する需要が高まっていました。
新しいミーリングカッターの形状は、ソリッドカーバイドドリルと多くの点で同じです。特別に設計された刃先形状がソフトカットを保証し、切削抵抗を軽減します。また工具の優れたプランジ加工特性により、部品への熱影響が最小限に抑えられます。
ソリッドカーバイドドリルと比較して、工具寿命が非常に長いアルミ合金のドライ加工用PCD工具は、工具寿命が非常に長いため、経済的な使用が可能です。高いツールコストはすぐに回収できます。