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.
PCD-粗加工铣刀用于干切
在加工机翼的铝结构件时,将切除原材料中大部分原有材料。针对机翼内的腔及凹槽的粗加工, MAPAL 公司在其产品组合中有一款整体硬质合金铣刀Opti-Mill- SPM-Rough, 该刀具优异的性能已经多次在实际加工中得到了证实。然而,该粗加工铣刀仅适于冷却液加工。这是因为: 整体硬质合金刀具在干切加工长切屑的铝合金时, 例如:在飞机制造中则碰到了极限。整体硬质合金刀具在加工中会很快形成刀瘤, 并且刀具磨损也明显增大。
由于在冷却液加工中,飞机机翼的空腔和凹槽很容易被冷却介质填充,因此MAPAL 公司适用于干切加工的的PCD-铣刀的需求量越来越大。
新铣刀的几何形状在许多方面与整体硬质合金刀具的几何形状相同。其特别设计的螺旋几何形状特别适于软切削加工并可极大降低加工力。同时还赋予该刀具出色的深入材料的特性。另外将传导到工件的热量也降低到最小。
由于PCD-刀具极长的使用寿命,在长切屑铝合金干切加工中,与整体硬质合金刀具相比,它的使用明显体现出更好的经济性。从而很快将在加工投入中刀具所占的高成本分摊收回。