10.03.2022

Titanium Machining Takes Off

There are numerous applications waiting for new titanium machining tools from MAPAL. In medical technology, this workpiece material is used for implants because of its strength and compatibility with human tissue. Automotive manufacturers use it to create powerful sports cars. The blades of large gas turbines, made of titanium, absorb enormous forces. The aircraft industry is producing more and more highly stressed parts made of titanium. MAPAL is making drilling and milling of the ductile, high-strength workpiece material more productive, thereby reducing costs.

#Aerospace #Automotive #Milling #Drilling #Produits #Technology #Industries
The picture shows an aeroplane and a sports car as representatives of important titanium application sectors.
  • The picture shows an aeroplane and a sports car as representatives of important titanium application sectors.
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    The range of applications for titanium as a material extends from medical technology to high-performance sports cars and the aircraft industry. ©GettyImages | Mark Evans 

  • The picture shows from left to right the NeoMill-Titan, two OptiMill-Titan-HPC solid carbide cutters and a MEGA-Speed-Drill-Titan solid carbide drill.
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    Innovative tools for milling and solid drilling of titanium. ©MAPAL 

  • Two MEGA-Speed-Drill Titanium solid carbide drills from MAPAL for machining titanium
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    Cost efficiency with the highest possible productivity – the new MEGA-Speed-Drill-Titan from MAPAL. ©MAPAL 

  • The solid carbide milling cutters OptiMill-Titan-HPC from MAPAL can be used both for roughing and for finish cuts in titanium.
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    The new OptiMill-Titan-HPC solid carbide milling cutter performs both roughing and final cuts in titanium very reliably. ©MAPAL 

  • A radial indexable insert milling cutter NeoMill-Titan from MAPAL.
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    The NeoMill-Titan milling cutter range for titanium machining with completely newly developed indexable inserts. ©MAPAL 

MAPAL's three new titanium tools

New drills and milling cutters made of solid carbide and milling cutters with indexable inserts extend MAPAL's standard portfolio for machining titanium. All three new developments feature high cutting values and well thought-out heat dissipation.

In designing the tools, MAPAL followed the requirements for titanium machining set by the target markets. The range of available diameters is correspondingly broad, starting with small sizes from 3 mm, as often required in medical technology, through the medium sizes for sports car components to the large tools for aircraft construction and energy technology. In tests, MAPAL has recorded 25 to 35 percent longer tool life for its tools compared to competitors.
 

MEGA-Speed-Drill-Titan: cost-efficient and productive

The focus in the development of the MEGA-Speed-Drill-Titan was on cost efficiency with maximum possible productivity. "Our goal was to develop a solid carbide drill that can run at a very high feed rate in titanium materials, resulting in very low cycle costs," explains Jens Ilg. In contrast to the assembly areas in aircraft construction, where no cooling lubricant or only a small amount of MQL can be used given the already finished assemblies, cooling lubricant can be used in parts production on machining centres to machine titanium efficiently.
Two MEGA-Speed-Drill Titanium solid carbide drills from MAPAL for machining titanium
Cost efficiency with the highest possible productivity – the new MEGA-Speed-Drill-Titan from MAPAL  ©MAPAL
MAPAL has equipped the drill with four guiding chamfers for optimum roundness. Convex cutting edges and an efficient coating allow for increases in tool life of up to 30 percent. To get the maximum coolant flow to the main cutter, the coolant channel is not open in the direction of the chip flute, but the coolant is guided along the outside surface to the rear. In this way, the guiding chamfers experience maximum cooling, dissipating the heat generated effectively. MAPAL uses a new design for the chip flute to produce the smallest possible chips and to discharge them through the flute. Typical parts that can be created with the drill, which achieves a cutting speed of up to 40 m/min, are structural parts in the aerospace industry, for example brackets for the wing box or the landing gear with its numerous bores.

OptiMill-Titan-HPC: versatile roughing and finishing

The solid carbide milling cutters OptiMill-Titan-HPC from MAPAL can be used both for roughing and for finish cuts in titanium.
The new OptiMill-Titan-HPC solid carbide milling cutter performs both roughing and final cuts in titanium very reliably  ©MAPAL

The OptiMill-Titan-HPC roughing-finishing milling cutter is a versatile tool. It is also ideal for smaller manufacturers who prefer not to have a single milling cutter for every kind of machining. The solid carbide tool can perform roughing operations and can also be used for a finish cut. The special cutting edge preparation produces clean surfaces and allows full slot milling up to 1.5xD. In conjunction with the MAPAL Mill Chuck, optimum coolant supply via the shank is possible. The core of this milling cutter with four cutting edges rises from the cutting edge to the shank, giving it greater stability. The spacing of the cutting edges and the pitch of the spirals are uneven to achieve smooth running. The coating, which contains silicon, and the polished chip flutes are highly heat-resistant, counteract the tendency to adhesion and therefore ensure optimum chip evacuation. The OptiMill-Titan-HPC milling cutters are available in the diameter range from 6 to 25 mm. Special dimensions are available.

The OptiMill-Titan-HPC is the number one tool for manufacturing titanium brake calipers for sports cars. MAPAL is also successfully using the tool to manufacture a wide range of parts for pilot customers. Rotor heads, door frames, flaps and structural parts for vertical tail planes (VTPs) are just a few examples.
 

NeoMill-Titan: indexable insert milling cutters with a bite

The NeoMill-Titan family of tools with indexable inserts for titanium machining consists of shell end face milling cutters in slip-on and shank versions as well as shoulder milling cutters in the standard portfolio. MAPAL has developed the topography of the indexable insert from scratch for optimum chip formation and evacuation. An equally new cutting material concept minimises wear and prevents the titanium from sticking. The available corner radii of 0.8 mm to 4 mm are tailored to structural parts in the aerospace industry. To save weight, several pockets are milled here, and their final contour should already be achieved as well as possible by pre-roughing. In the manufacturing of tail fin structures, about 90 percent of the material is removed.
Ein radialer Wendeschneidplattenfräser NeoMill-Titan von MAPAL.
NeoMill-Titan Fräser für die Titanbearbeitung mit komplett neu entwickelten Wendeschneidplatten  ©MAPAL

Die Wendeschneidplatten bietet MAPAL mit zwei verschiedenen Substraten an. Eine Sorte ist für universelle Anwendungen konzipiert und richtet sich an Kunden, deren Fokus eher auf dem Produktpreis und weniger auf den Kosten pro Bauteil liegt. Die zweite Sorte ist temperaturfester und erlaubt so höhere Schnittgeschwindigkeiten und die Bearbeitung höher vergüteten Titanmaterials. Erreicht werden Schnittgeschwindigkeiten bis 70 m/min. „Mit diesem Ansatz gehen wir konkret auf die Anforderungen des Marktes ein“, erläutert Dr. Piotr Tyczyński, Global Head of Segment Management Aerospace & Composites. „Wir berücksichtigen die individuellen Bedürfnisse unsere Kunden und bieten eine optimal passende Lösung an.“ 

Für die Hochtechnologieschneiden wurde auch der Werkzeugkörper neu entwickelt. Mit fließenden Formen befördern die Spannuten den Span aus der Scherzone. Die Ungleichteilung der Schneiden sorgt für zusätzliche Stabilität und Laufruhe. Das Kühlmittel wird direkt über den Fräsdorn axial zugeführt. Der ganze Fräser ist im Prinzip ein Hohlkörper mit einer großen Kammer in der Mitte, aus der das Kühlmittel zu jeder Schneide transportiert wird. Die Kühlmittelaustritte sind variabel gestaltet, durch Tauschen eines Gewindestifts kann der Bediener die Durchflussmenge für jede einzelne Schneide regulieren. 

Die Eckfräser für Titan bietet MAPAL in Durchmessern von 40 mm bis 125 mm ab Lager an. Die Walzenstirnfräser sind von Durchmesser 32 mm bis 80 mm lagerhaltig. Sonderabmessungen sind auf Anfrage ebenfalls erhältlich.
 

Kathrin Rehor, PR Project Manager bei MAPAL

Kontakt

Kathrin Rehor Public Relations Kathrin.Rehor@mapal.com Tel.: +49 7361 585 3342

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