PCD for machining challenging aviation components

When machining the structural components of aircraft wings made of aluminium, a large portion of the existing material is removed by machining. For roughing the chambers or pockets inside the wing MAPAL has a solid carbide milling cutter, the OptiMill-SPM-Rough, in its portfolio, and this has already proven its performance many times over. However, this roughing cutter is only suitable for wet machining. Because: Solid carbide tools reach their limits when dry machining long-chipping aluminium alloys, such as those used in aircraft construction. Built-up edges quickly form, and the tools are subject to significant excessive wear.

There was an increasing demand for a tool for dry machining corresponding to the PCD-tipped milling cutter from MAPAL so that the chambers and pockets on the wing do not fill up with the cooling medium.

The geometry of the new milling cutter is in many ways identical to that of its solid carbide counterpart. The specially designed knurled roughing geometry ensures a soft cut and reduces process forces. It also gives the tool excellent plunging properties. The heat input into the component is minimal.

Due to the considerably longer tool life of the PCD tool when dry machining long-chipping aluminium alloys compared to that of its solid carbide counterpart, its use is significantly more economical. The higher tool costs are quickly amortised.