The Right Tool at the Right Time

High Performance Tools forAerospace Applications

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Adding Value to your Business through Strategic Partnership

Introduction .......................................................................................................................... 4

Airframe ................................................................................................................................ 6

Aluminium components .................................................................................................. 8

Composite components ................................................................................................ 10

Landing Gear ..................................................................................................................... 12

Engine ................................................................................................................................. 14

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Machining SolutionsThe characteristics of many materials used in aerospace components present numerous machining issues. To address these points, Dormer has invested in a Research and Technology Centre (RTC) where extensive development work on cutting tool geometries, substrates, coatings and application solutions is carried out.

Another major focus for the RTC is the research of aerospace component materials and, in particular, composite materials, their structures and machining characteristics.

Work in this area has led to tooling developments aimed specifically at eliminating the potential problems encountered when machining composite materials and to deliver:

Increased tool life

High quality holes

Lower cutting forces and working temperatures

Delamination-free holes

Reduced splintering and fraying

Overall process efficiency improvement

For all your aerospace component machining needs, contact your local Dormer Engineer.

Exceptional Tools and Expertise forChallenging Aerospace ApplicationsThe Aerospace industry is one of the most technically demanding in the world. With difficult to machine materials and very strict specifications, the manufacture of aerospace components requires a very competent tooling partner. Dormer is committed to offering complete tooling solutions to produce aerospace components, such as the airframe, landing gear and engine. This is both the physical tool - whether a standard or an engineered product - but also the machining knowledge.

The Dormer offer encompasses:

Extensive CapabilitiesThe range is designed for all aerospace component materials from aluminium alloys, high strength alloys, heat resistant alloys, Polymer Matrix Composites (PMCs), also known as Fibre-Reinforced Polymers (FRPs), to Carbon and Glass-Fibre Reinforced Polymers (CFRPs and GFRPs).

The Dormer range for composite materials is also recommended for “Stack” materials comprising of Carbon and Glass-Fibre joined to metals such as Aluminium, Stainless Steel or Titanium.

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Technology and ExpertiseBy working closely with specialists at the forefront of technology, Dormer has built valuable, in-depth expertise in the field of aerospace component machining. Partnerships with leading universities and research centres around the world provide Dormer with a unique perspective into the latest machining technologies.The result is a range of tools designed specifically to overcome the challenges encountered when machining aerospace components in aluminium, high strength steels, heat resistant alloys and composite or composite stack materials.

Tailored Tooling SolutionsDue to the wide range of requirements for machining aerospace components, Dormer works in partnership with each customer to ensure that every tooling solution offered is optimised for each individual application. Whether your application calls for hand-held carbide tools or CNC-operated PCD tooling, Dormer can provide a solution tailored to your specific needs.

Reconditioning / RegrindingAn efficient regrind or reconditioning service is offered with all Dormer products. This includes recoating (where applicable) and guarantees the quality and performance of the tool for up to three regrinds.

Strategic PartnershipsWorking in partnership with Dormer gives customers direct access to the RTC and the support it offers. This includes increasing productivity and reducing costs involved in the manufacturing process.

We focus on: Reducing downtime, optimising the cutting process, and optimising the end result in terms of surface finish, hole tolerance and quality

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10mm 4mm

AirframeThe airframe is the mechanical structure of an aircraft and combines many different materials and manufacturing methods. The main materials used are Aluminium, High Strength Alloys and Composites. Due to the different combinations of materials and the access problems faced when machining, many different types of tools are used to manufacture this section of the aircraft.

One of the most common manufacturing procedures on the airframe is drilling thousands of rivet holes used to attach the skin to the structure. This often has to be undertaken in a number of steps but, under the correct conditions and with the right tools, can be achieved in one operation.

With a focus on reduced downtime, improved hole quality and tolerance, Dormer offer tailored solutions in close collaboration with the customer.

Carbide DrillsDormer’s carbide drills are designed for CNC and semi-automated operations. Thanks to their unique geometries, these specialised tools reduce thrust and torque, lower cutting temperatures and improve hole quality and tolerance.

Conventional DrillsThe Dormer range of Aircraft Drills to NAS specifications are designed for handheld drilling in airframe applications and offer consistently high process quality combined with excellent tool life.

The R790 design produced excellent quality holes, showing no signs of delamination or splintering on the Carbon Fibre and no signs of any exit burr on the aluminium.

Challenging One-Shot DrillingSolution of Wing Skin Assembly

Tool Desc: R790 Carbide Composite DrillMachine: Portable Drilling UnitDrill Ø: 11/64”Speed: 5,200 rpmFeed: 70 mm/min

AluminiumCarbonFibre

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Rivet DrillsDormer’s rivet drills are designed for automated, precise, “one-shot” drilling of countersunk holes, facilitating increased tool life and reduced cost- per-hole. Available with various coatings in HSS, HSCo, Carbide and PCD to accommodate a range of airframe structures and materials.

CountersinksWhilst the primary objective with one-shot tooling is to minimise production time, the finishing of a hole may require a second operation. For tight tolerance holes or a demanding surface finish, Dormer offer a full range of carbide and PCD countersinks.

Offering increased flexibility and reduced stockholding requirements, Dormer countersinks with replaceable pilots enable different sized countersunk holes to be produced with one tool.

Core Drills and ReamersWhen a one-shot operation is not feasible, Dormer core drills and reamers allow precise enlargement of existing holes.

Available in HSCo, Carbide and PCD, all are manufactured to aerospace standards and customer specifications.

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Aluminium ComponentsMany large structures within the aircraft - such as Ribs and Spars - are manufactured from aluminium. Due to their complex geometry, these components begin as large billets of aluminium, with a large percentage of the material being machined away. To do this efficiently, high speed machining techniques are employed which calls for the use of high performance milling cutters. Thin wall sections with varying heights and thicknesses require specific tooling geometries and machining strategies.

For these operations Dormer offer a complete range of high performance solid carbide milling cutters, drills and threadmills as well as high performance taps specifically designed for machining aluminium alloys.

Carbide DrillsDormer offer tools capable of exceptional performance in materials where high productivity is crucial and, therefore, high cutting speeds are demanded. The R583 and R587 drills are designed specifically for the high performance machining of aluminium alloys.

Both drills feature Dormer’s patented point geometry which significantly reduces thrust forces at high penetration rates, eliminating exit burr. Thanks to their unique design, the aluminium drill range promotes excellent chip management in a wide range of aluminium alloys, from soft to the most abrasive grades.

High Performance Taps for AluminiumDormer’s programme covers a wide range of thread forms manufactured to DIN/ANSI standard, including M, MF, UNC and UNF.

The E448 & E449 spiral point taps for through holes and E450 & E451 spiral flute taps for blind holes allow increased performance and wear resistance due to a combination of their special geometry and ZrN coating.

Offering increased tool life when machining abrasive aluminiums with high silicon content, solid carbide spiral flute taps are also available in both solid (T105) and coolant feed (T106) designs.

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Carbide Milling CuttersDormer provide a total solution from roughing to finishing. The optimum choice for roughing are the S140, S143, and S145. All have reinforced end teeth to equip them for tough machining conditions.

The S142 gives exceptional performance in super-finishing operations and can achieve 4xD axial depth.

The S149 has been specifically designed for deep pocket milling and profiling. Its reduced shank diameter allows the user to adjust the length of the tool projecting from the tool holder in order to optimise performance.

For contouring and 3-D forming, the S540 (ball nose) and S144 (corner radius) are particularly suited for the high speed machining of complex surfaces.

Dormer S145 - Measurement of tool vibrations atbeginning of cut on 75th slot after 30 minutes of cutting.

Competitor 2 - Measurement of tool vibrations atbeginning of cut on first slot – tool broke at second slot.

Demanding operationin Aluminium

Thanks to low vibration, Dormer’s S145 achieved excellent surface finish and tool life.

OperationDeep slotting operation, milling closed slots in two passes.

Tool diameter: 10 mmAp: 0,5 x Ø = 5 mm (each pass)Ae: 1,0 x Ø = 10 mmSpeed: 15,000 rpmFeed, plunging: 600 mm/minFeed, slotting: 2,400 mm/min

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Composite ComponentsComposite materials have a very high strength to weight ratio and are, therefore, rapidly becoming more popular in aircraft manufacture. Due to their structure and machining properties, they are very difficult materials to process in terms of drilling and profile milling.

To avoid delamination of the layers and splintering of the fibres, special geometries have to be applied to machine them efficiently. As most machining operations must be performed without coolant, aggressive abrasion can lead to high temperatures, causing premature tool wear.

Dormer’s tailor-made tooling solutions in PCD and Carbide provide excellent temperature resistance, allow increased speeds and feeds with superior tool life and finish, thereby reducing downtime and increasing productivity.

Composite Drills: Carbide/PCDDormer’s drills for composite and composite/stack materials are primarily designed for semi-automated and CNC operations.

Their unique geometries generate lower cutting temperatures and reduce thrust and torque. This helps to eliminate delamination and splintering and, in turn, results in improved tool life, hole quality and tolerance.

Rivet Drills: Carbide/PCDWith a focus on reduced downtime and increased precision, Dormer PCD rivet drills are designed for automated “one-shot” drilling of countersunk holes. Also available in a modular design to enable the drill point to be changed and, therefore, total costs to be reduced.

Composite Hand DrillsDormer’s carbide composite drills for manual and semi-automated operations produce excellent quality holes.

With geometries specifically designed to reduce breakthrough surge, the risk of delamination and splintering is minimised.

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25mm 25mm25mm 25mm

PCD CountersinksFor demanding operations in composite materials, Dormer offer a full range of PCD countersinks for increased tool life.

PCD Milling CuttersThe rigid design of Dormer’s PCD milling cutters for high speed machining minimises vibration, improving component surface finish and significantly increasing tool life.

CarbonFibre

CarbonFibre

Competitor Result:When glass cloth is used on the exit face of composite materials it is extremely difficult to produce a hole with a perfectly clean periphery.

Dormer Result: Dormer’s new geometry is capable of consistently delivering holes with excellent exit quality, showing no signs of delamination, splintering or fraying of the glass cloth exit face.

Drilling composite stack with glass cloth exit face

Machine: CNCDrill Ø: 10mmStack Thickness: 50mm Glass Cloth

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Landing GearTo endure the major impact stresses that landing gear systems are subjected to, they are generally manufactured from ultra high strength steels such as 300M. Recent developments and the need for weight reductions has seen the introduction of other alloys such as Titaniums and even Composites. The nature and design of the components and the types of materials used means that machining can be challenging, with deep bores and complex features calling for specific tool designs and geometries.

Carbide Milling CuttersDormer can provide a total solution - from roughing to finishing - in ultra high strength alloys.

The HRA asymmetric geometry of the S335 is specifically suited to reducing vibration thereby increasing tool life in roughing operations.

HSCo-XP Milling CuttersFor applications in very tough materials or under less stable working conditions, Dormer’s HSCo-XP milling cutters offer superior toughness and, consequently, improved performance.

Dormer

R570

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Cost per Hole Comparison in Alloy Steel (P20) Ø 8.0mm, Cutting Depth 8 x Ø (30 mins)

The graph shows the cost per hole of Dormer’s R570 drill against three competitors equivalent drills, running at each company’s recommended cutting conditions over a period of 30 minutes.

HSCo Drill vs R570 Cost per Hole Comparison in Alloy Steel (P20) Ø 8.0mm, Cutting Depth 8 x Ø (30 mins)

The graph shows that a significant reduction in cost per hole can be achieved by using Dormer’s R570 drill compared to the HSCo TiAIN coated drill.

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The unequal helix and divide technology of the S250, S252, S254 and S255 increases stability during machining. Specific design features reduce tool vibration and the risk of chipping, increasing metal removal rates and, therefore, allowing the tools to be run at high speeds and feeds.

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Carbide DrillsWith the R570, R571, R572, R573 and R575 drills specifically designed for one-shot deep hole drilling and the R553 and R554 for drilling in high strength alloys, Dormer offer tools with exceptional performance. The Hydra replaceable head drilling solution offers flexibility, reduced inventory and consistently high performance, even after numerous head changes.

ReamersWhen precise accuracy, concentricity and roundness of holes is required in high strength alloys Dormer’s range of NC reamers perform effectively up to a hardness of approximately 63 HRc. The extremely unequal spacing of the cutting edges has the additional effect of enhancing hole quality, ensuring outstanding results.

High Performance Taps forHigh Strength AlloysDormer offer a complete range of taps specifically engineered for threading in high strength alloys, covering a wide range of thread forms manufactured to DIN/ANSI standard, including M, MF, UNC and UNF.

The special geometry incorporated within the E396, E324 and E326 spiral point taps for through holes and E394, E314 and E316 spiral flute taps for blind holes guarantees increased performance and tool life.

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ReamersWhen precise accuracy, concentricity and roundness of holes is required in heat resistant alloys Dormer’s range of NC reamers will perform effectively up to a hardness of approximately 63 HRc.

The extremely unequal spacing of the cutting edges has the additional effect of enhancing hole quality.

EngineMaterials used in the manufacture of aircraft engines can differ greatly according to their location within the engine. Due to the extreme forces and temperatures incurred during service, the materials involved are normally high strength and high temperature resistant alloys such as Titanium, Inconel and Waspalloy.

The complex composition of these materials, means they can be very difficult to machine with conventional tooling, calling for special geometries and specific machining strategies.

Carbide Milling CuttersOne of the main benefits of the S256 unequal helix end mill is its flexibility. It will remove large amounts of metal but, unlike a traditional roughing end mill with chipbreaker profile, the S256 gives a high quality finish on the component, thus eliminating the need for a second operation.

A range of cutters designed for 3-D contouring in tough materials is also available. For example, the S503 and S290 with precise ball nose and corner radii are ideal for machining in difficult to reach areas.

HSCo-XP Milling CuttersFor some difficult applications or under less stable working conditions Dormer’s HSCo-XP milling cutters offer superior toughness and therefore improved performance.

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Carbide DrillsWith the high performance R563 and R567 drill ranges specifically designed for drilling in heat resistant alloys, Dormer provide tools with outstanding performance capabilities.

Dormer’s R570, R571, R572, R573 and R575 deep hole drills can be applied on numerous engine components with excellent results.

High Performance Threadmills for Heat Resistant AlloysTo ensure high process security when producing threads in critical components, Dormer has a full range of solid carbide threadmills, all of which offer outstanding reliability and performance.

The graph shows the difference in surface roughness between S256, 12 mm and equivalent competitor end mills during finishing operation in AISI 304 at Dormer recommended cutting parameters.Radial depth (mm) 0.1 x D = 1.2 mmAxial depth (mm) 1.5 x D = 18 mm

The graph shows the tool life of the S256, 12mm against equivalent competitor end mills during finishing operation in 17-4PH, up to a maximum of 0.2mm wear.Radial depth (mm) 0.1 x D = 1.2 mmAxial depth (mm) 1.5 x D = 18 mm

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The Right Tool at the Right Time

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