High Performance Machining of Titanium The Systems Approach · Tunable Milling Adapter Beyond BlastTM ... 1000 950 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150

October 5th, 2011

T.J. Long, Ruy Frota, and Steve Chen

Kennametal Technology Center

Latrobe, PA

High Performance Machining of Titanium

The Systems Approach

Agenda

• Challenges in machining Titanium

• Thermal Management

• Importance of Spindle Connections

• Maximizing Dynamic Stiffness

© 2011 Kennametal Inc. l All rights reserved. l Proprietary and Confidential l 1

KM4XTM

Tunable Milling

Adapter

Beyond BlastTM


Challenges in Machining Titanium

90% of work from metal

cutting is converted into

heat

X (mm)

Y(m

m)

4.8 4.9 5 5.1 5.2 5.3

1.8

2

Temperature (C)

1000

950

900

850

800

750

700

650

600

550

500

450

400

350

300

250

200

150

100

Third Wave AdvantEdgeThird Wave AdvantEdge • Good high temperature strength

increases the work needed to cut

Titanium.

• High work hardening and strain rate

sensitivity exacerbate thermal issues

in cutting Ti alloys.

• Titanium reacts with most materials

at high temperatures to chemically

wear tools.

• Poor thermal conductivity of Ti

causes heat to partition to the tool

instead of the chip.

Titanium Characteristics

Time (s)

Fo

rce

-X(N

),F

orc

e-Y

(N)

Te

mp

era

ture

(C)

0 0.001 0.002 0.0030

100

200

300

400

500

600

700

0

200

400

600

800

1000Force-X (N)

Force-Y (N)

Temperature (C)

Time (s)

Fo

rce

-X(N

),F

orc

e-Y

(N)

Te

mp

era

ture

(C)

0 0.0005 0.001 0.00150

200

400

600

800

1000

0

200

400

600

800

1000Force-X (N)

Force-Y (N)

Temperature (C)

50 m/min at 0.15 mm chip 100 m/min at 0.15 mm chip

Effect of Cutting Speed on Temperature

Increase Tool Temp +250oC

Current Ti cutting conditions Double Cutting Speed

FEM predicts a 250°C increase in cutting temperature to

double speed


0.00

0.50

1.00

1.50

2.00

2.50

Rela

tive T

oo

l L

ife

Std Coolant Beyond Blast

T124755 KSSM 45° Lead Angle

Beyond Blast vs. Standard Through Coolant

KSSM45 Milling Tool Development

KSSM45 Beyond BlastTM provided over 2 times better tool life than

standard through spindle coolant delivery.

Cutting Conditions

Workpiece: Ti6Al4v

Hardness: 42 – 46 HRC

Length of Pass: 254mm (10 in)

Cutting Fluid: Water based Synth.

Coolant Pressure: 300 psi.

Cutting Parameters

Cutting Speed: 58 m/min (187 SFM)

Chip load (fz): 0.25mm/tooth(0.010 ipt)

Axial Depth of Cut = 2 mm (0.08 inch)

Radial Depth of Cut = 81 mm (3.2 inch)

Baseline


0.00

0.50

1.00

1.50

2.00

2.50

3.00

Re

lati

ve

To

ol L

ife

Std Coolant

150 SFM

Beyond Blast

150 SFM

Std Coolant

187 SFM

Beyond Blast

187 SFM

T114526 & T117470 Daisy Round Inserts

Beyond Blast vs. Standard Through Spindle Coolant

Std Coolant

Beyond Blast

Daisy Milling Tool Development

DAISY Beyond BlastTM provided over 2.5 times better tool life than

standard through spindle coolant delivery @ 150 SFM.

Cutting Parameters


& 58 m/min (187 SFM)

Chip load (fz): 0.25mm/tooth(0.010 ipt)

Axial Depth of Cut = 3.8 mm (0.15 inch)

Radial Depth of Cut = 51 mm (2.0 inch)

Cutting Conditions

Workpiece: Ti6Al4v


Length of Pass: 254mm (10 in)


Coolant Pressure: 1000 psi.

Baseline



Turning Facing Profiling Square Shank

R S

tyle

Op

era

tio

ns

Coolant Path Shim position determines coolant path

• Shim side 1 up

• Rotate shim 90°

for facing

• Shim side 2 up (flip

shim over)

• Broader coolant

dispersal for profiling

• Shim side 1 up

• Position coolant

slot toward end for

turning

Technical details – R Shape Geometries

Cutting Parameters


Feed: 0.2 mm/rev (0.008 ipr)

Depth of Cur: 1.27 mm (0.05 inch)

Cutting Conditions

Workpiece: Ti6Al4v



Coolant Pressure: 100 and 1000 psi.

Cutting Conditions

Workpiece: Ti6Al4v



Coolant Pressure: 100 and 1000 psi.

Cutting Parameters

Cutting Speed: 30 and 45.5 m/min (100 and 150 SFM)

Feed: 0.305 mm/rev (0.012 ipr)

Depth of Cur: 6.35 mm (0.25 inch)


Turning Tool Development

Agenda






KM4XTM

Spindle Connections - Overview

Where we are today…

ASME B5.50

DIN 69871

ISO 7388

JIS B6339

ISO26622

(KM System)

DIN 69893

ISO12164

(HSK)

ISO26623

(PSC System) ISO 7388

With Face contact

Kennametal’s Next Spindle

Generation of KM™


KM4X Next Generation Spindle Connection

Kennametal’s Next Spindle

Generation of KM™

• Highest rigidity and bending capacity

among all connections

• Evenly distributed clamping force

• Simple design allows for front-loaded

spindle configurations

• Balanced by design for high spindle

speed capability

• Capable of performing in a wide range of

operations from low speed, high torque to

high speed, low torque.


Load-Deflection Charts KM4X63 versus PSC63

KM4X63 shows higher stiffness and separation bending moment than PSC63 at same clamping force


Load-Deflection Charts KM4X63 versus HSK63

KM4X63 shows 4X higher stiffness at 600 Nm and 8X at 900 Nm


1.00 1.00

0.86

0.270.21

0.080.06

0.82

0.440.36

0.140.19

0.060.06

0.37

0.160.14 0.09

0.17

0.05 0.05

0.00

0.20

0.40

0.60

0.80

1.00

1.20

No

rmalized

Sti

ffn

ess

1800 3000 6000

Bending Moment [N.m]

KM4X125

KM4X100

HSK125A

HSK100A

CV60

BCV50

CV50

Load-Deflection chart

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0 1000 2000 3000 4000 5000 6000

Bending Moment [Nm]

Defl

ecti

on

[m

m]

@150m

m

BCV50

CV50

HSK100A

KM4X100

Load-Deflection chart

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

0.20

0 1000 2000 3000 4000 5000 6000

Bending Moment [Nm]

Defl

ecti

on

[m

m]

@150m

m

CV60

HSK125A

KM4X125

Load-Deflection Charts KM-HSK-Steep Taper


Cutter Diameter: 80 mm

Number of flutes: 4

Projection Length: 250 mm

Cutting Speed: 50 m/min

ADOC: 63.5 mm

RDOC: 12.7 mm

Feed Rate: 142 mm/min

MRR: 361 cm3/min

Torque: 870 Nm

Bending Moment: 4620 Nm

MRR is limited by maximum the bending moment of spindle interface

0

500

1000

1500

2000

2500

3000

3500

4000

0 500 1000 1500 2000

Spindle Speed [rpm]

To

rqu

e [

Nm

]

Spindle Torque Curve Operating Point Torque Limited by Bending

Application Data – Ti Milling on HSK125A machine

Cutter Diameter: 300 mm

Number of Inserts: 20

Projection Length: 150 mm

Cutting Speed: 46 m/min

ADOC: 9.5 mm

RDOC: 150 mm

Feed Rate: 195 mm/min

MRR: 284 cm3/min

Torque: 2905 Nm

Bending Moment: 2860 Nm 0

500

1000

1500

2000

2500

3000

3500

4000

0 500 1000 1500 2000

Spindle Speed [rpm]

To

rqu

e [

Nm

]

Spindle Torque Curve Operating Point Torque Limited by Bending


Agenda






Tunable Milling

Adapter

Tunable Adapters provide significantly higher dynamic stiffness

Tunable Milling Adapters

Acceleration vs. Dynamic Stiffness

0.06

0.07

0.08

0.09

0.1

0.11

0.12

5.00E+06 7.00E+06 9.00E+06 1.10E+07 1.30E+07 1.50E+07

Dynamic Stiffness (N/m)

Accele

rati

on

(m

/s2)

Normalized Dynamic Stiffness

0.00

0.20

0.40

0.60

0.80

1.00

1.20

0 1 2 3 4 5 6 7 8 9Number of turns

SK50 L=300mm

SK50 L=260mm

• Optimal Dynamic Stiffness. Adapter can be tuned on the spindle to account for machine dynamics

• Improved surface quality and close tolerances

• Increased productivity. Larger depth of cut and feed rate.

• Significant reduction on vibration for extended tool life, longer spindle bearing life

0.76

0.25

1.00

0.32

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

Dyn

am

ic S

tiff

ness (

No

rmali

zed

)

Machine A Machine B

Dynamic Stiffness of Damped Milling Adaptors

Tunable Standard Toolholder


It’s Not Just About the Tools:

It Is About Partnerships, Digitization and Integration

Design Part

with CAD

Select

Machine Select Tools

Write & Optimize

Program Produce Part Inspection

That Can be Optimized

A Complex Iterative Process

0 10 20 30 40 50 60 70 80 90 100

Optimized

Baseline

Forging/Casting Machine Tool Cutting Tools Machining Other

The Opportunity


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http://en.wikipedia.org/wiki/Image:Ugs-nx5-mold-tooling.jpg

http://en.wikipedia.org/wiki/Image:Ugs-nx5-mold-tooling.jpg


Documents

High Performance Machining of Titanium The Systems Approach · Tunable Milling Adapter Beyond BlastTM ... 1000 950 900 850 800 750 700 650 600 550 500 450 400 350 300 250 200 150