WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN
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1 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN
2 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
3 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
4 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
5 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
6 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
7 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
8 MAPAL IS A FAMILY-OWNED COMPANY HIGH-QUALITY & -VOLUME PRODUCTION. Established by Dr. Georg Kress Entrance Dr. Dieter Kress Entrance Dr. Jochen Kress Reaming Tool Concentration on guide padded tools for the fine machining of bores Continuous improvement of the product range 2008 Start BU Aerospace Wing & Fuse Assembly
9 MAPAL IS A GLOBAL COMPANY CLOSE TO THE CUSTOMER. Subsidiaries with regional production, sales and service in 21 countries 4000 employees worldwide, approx. 2,000 are in Germany Technical and sales representatives in 25 countries
10 REFERENCES OF MAPAL USERS AEROSPACE APPLICATIONS
11 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
12 PRODUCT PROGRAM, AEROSPACE PART MACHINING Solid Carbide Drills Honey Comp Tool for Wind Plade machining PCD Tools Fine Boring Tools with Guide Pads Generating Tools Indexable End Mill Reaming Tools Adapter HSK - X Setting Fixtures
13 PRODUCT PROGRAM, AEROSPACE ASSEMBLY Solid Carbide & PCD Drills Green Tools 1 shot H8 Stack drilling Hand Held tools Solide Carbide Hand Held tools HSSE Indexable Drill Tips 2 shot Drilling Tools Indexable Threated Adapter Heat shrink Adapter HSK - X
14 CUTTING TOOLS AND TECHNOLOGY R&D You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
15 RESEARCH & DEVELOPMENT IN AALEN EMPLOYEES AND MACHINERY Engineers: 11 Technicians: 6 Specialised staff: 4 Prototype machining: 6
16 RESEARCH & DEVELOPMENT IN AALEN AEROSPACE DEPARTMENT 14 Kompetenz in Composite
17 COMPLETE MEASUREMENT AND TEST EQUIPMENT TRIAL ANALYSIS AND TOOL GAUGING
18 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
19 HIGH REQUIREMENTS ON EDGE MILLING FOR AEROSPACE CFRP PARTS
20 TRIMMING OF AEROSPACE COMPOSITES AEROSPACE CFRP PARTS
21 TRIMMING OF AEROSPACE COMPOSITES AEROSPACE CFRP PARTS - There is no part produced with Netshape process - All parts have to be trimmed / milled / drilled in post manufacturing process
22 TRIMMING OF AEROSPACE COMPOSITES AEROSPACE CFRP PARTS What type of cutter? Succesfull Process How much it cost? How to use it?
23 TRIMMING OF AEROSPACE COMPOSITES AEROSPACE CFRP PARTS TECHNICAL ASPECTS ECONOMICAL ASPECTS
24 TRIMMING OF AEROSPACE COMPOSITES AEROSPACE CFRP PARTS TECHNICAL ASPECTS ECONOMICAL ASPECTS
25 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites TECHNICAL ASPECTS F f Process Limit f For feed lover then 1m/min the use of climb milling is recommended Climb milling for larger tool life Conventional milling for high chip removal rate
26 TRIMMING OF AEROSPACE COMPOSITES TECHNICAL ASPECTS Geometric of the tool is similar to cutting Aluminium Cutting Strategy Goals for cutting the customer relevant surface: Cracks in line of feed direction Maximum of dust removal capability Low Temperature Conventional milling Climb milling Chip Customer relevant Surface quality Cut off feed MAPAL Solutions
27 TRIMMING OF AEROSPACE COMPOSITES TECHNICAL ASPECTS F c F ges F f F f F p F ges F p F c crack crack feed climb milling conventional milling MD-PS-AIR E-a
28 TRIMMING OF AEROSPACE COMPOSITES TECHNICAL ASPECTS High pressure due overloaded to dust removal capacity climb milling conventional milling feed MD-PS-AIR E-a
29 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites TECHNICAL ASPECTS climb milling conventional milling hot spot high Thermal infusion of the boundary layer low feed
30 High requirements on Edge milling Aerospace Carbon fiber-reinforced plastics parts TRIMMING OF AEROSPACE COMPOSITES TECHNICAL ASPECTS Cutting the fibre under stable condition Cutting the fibre under unstable condition crack crack feed Finishing high quality Roughing high chip removal
31 TRIMMING OF AEROSPACE COMPOSITES AEROSPACE CFRP PARTS TECHNICAL ASPECTS ECONOMICAL ASPECTS
32 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites ECONOMICAL ASPECTS Machining of 228 linear ft Characteristic Solid Carbide CVD PCD Brazed PCD Veinded Cost / tool (US $) Machining time (min) Quantity of tools Tools total cost Tool cost / hour Cost / linear ft
33 TRIMMING OF AEROSPACE COMPOSITES ECONOMICAL ASPECTS v f = 100 m/min = 33 sfm f = 0,1mm/rev =.004 High Performance Low Noise Continuous Wear Fail Save
34 High requirements on Edge milling Aerospace Carbon fiber-reinforced plastics parts TRIMMING OF AEROSPACE COMPOSITES CASE STUDY
35 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites CASE STUDY The present project deals with edge trimming (Routing) of Carbon Fiber Reinforced Epoxy Panels. The Objectives are as follows: 1 Select the best tool for the machining process 2 Select the right cutting parameters(spindle Speed and Table feed) 3 Select the depth of cut 4 Determine the tool life for a better cost / part or cost / linear ft.
36 High requirements on Edge milling Aerospace Carbon fiber-reinforced plastics parts TRIMMING OF AEROSPACE COMPOSITES CASE STUDY Cutting Tool selection - Mapal offer a wide range of composite end mills for panels or parts edge milling. - Based on the type of CFRP constituants (Resin & Fibers), we decided to go with the recent developped end mill - The selected end mill number is with 8 flutes (see drawing)
37 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites CUTTING PARAMETERS Test Tool No.: Material Dc (mm) Z Vc (m/min) RPM U/min Fz (mm) fz eff (mm) Table feed (mm/min) Ap (mm) Ae (mm) Dust Q - MRR ( l/min) CFRP CFRP CFRP , , , , , , Selected cutting parameters after test 1 Dc Z Vc RPM Fz Fz eff Table feed Ap Ae Dust Q-MRR Diameter of cutter Number of flutes cutting speed Spindle speed feed per teeth effective feed Table feed cutting depth cutting width Dust Volume
38 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites CASE STUDY Very good conditions of the Cutting edges after 1 st and 2 nd panel sides end milling No defects on the coating or the tool cutting edges after 3rd panel sides end milling
39 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites CASE STUDY - Both test panels 2 and 3 were trimmed using the selected cutting parameters after trials at 4000, 6000 and 8000 RPM Trimmed surface for test panel 2 - Trimmed surfaces show a very smooth finish - No Macroscopic porosity (high quality Laminate) - Microscopic pictures doesn t show any fiber pullout or resin extraction Trimmed surface for test panel 3
40 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites CASE STUDY - MAPAL selected an 8 straight flutes CVD diamond coated COMPOSITE END MILL for parts edge milling - Cutting conditions were also selected based on cutter size as well as material (Composite) constituents type - Cutting conditions were verified on test panel 1 - Results obtained on test panel 2 & 3 showed very smooth surface finish of all trimmed edges
41 High requirements on Edge milling Aerospace Carbon fiber-reinforced TRIMMING OF AEROSPACE plastics partscomposites CASE STUDY ADVANTAGES USING MAPAL CUTTERS Optimized cutting parameters No heat affected zones No delamination, splintering, fraying edges or any other integrity problems No Post-processes are needed Process automation and multi-operations are possible Versatile for different composites and laminated structures
42 WIRTSCHAFTLICHES BOHREN UND FRÄSEN VON COMPOSITE VERBUNDWERKSTOFFEN You looking forward to receive a economic and safe working solution Tailor Made Solution We have the energy and know how to support you with innovative solutions. MAPAL WW PRODUCTS R&D TRIMMING DRILLING WHAT WE CAN DO FOR YOU
43 DRILLING CFK/TITAN/ALUMINIUM REQUIREMENTS Tool geometry must consider: - Diameter has to be constant over tool life end. - Entrance burr <0,05, Exit burr < 0,1 - Cost per hole C/A < 0,1, C/T < 0,5 - No fibre overhang on CFRP. - No delamination on CFRP. - Temperatures lower 130 C - Always being fail save - One Way Assembly - Dry Drilling Dornfeld: Strategies for Burr Minimization and leanability in Aerospace and Atomotive Manufacturing
44 PROCESS UNDERSTANDING PHYSICAL EXPLANATION Cutting Metal Cutting Composite Work piece softer than cutting tool material Cutting by plastic deformation & shearing off metal chips Heat generated removed with chip evacuation process Carbon fibers are extremely hard and abrasive Cutting carbon fibers by series of fracture mechanics Heat generation affects the CFRP matrix thermal performance Function of Temperature Heat is generated while cutting No Function of Temperature No Heat is generated while cutting
45 DRILLING OF COMPOSITE METALL STACKS SELECTION TO START WITH Metal - Technology MAPAL - Titan Composite - Technology special features MAPAL CFRP - MD
46 PROCESS UNDERSTANDING ANALYSIS OF THE RESULT Theory Analysis
47 TECHNOLOGY TO COMPENSATE THE THERMAL GAB MICRO REAMER Micro Reamer H9: 40µm H8: 17µm ALU CFRP ALU 2 shot drilling & Reaming ALU ALU CFRP CFRP Titan Titan 1 shot drilling with Micro Reamer
48 TECHNOLOGY TO COMPENSATE THE THERMAL GAB MICRO REAMER After Reaming ALU CFRP Titan Before Reaming After Reaming 1 shot drilling Before Reaming
49 HOLE QUALITY ONE SHOT DRILLING TITAN / CFRP / TITAN Micro Reamer CFRP IM - M21E Titan TiAl6V4 CFRP/Titan Stack Drill
50 RESULTS - DRILLING ONE SHOT COMPOSITE / ALUMINUM - FUSELAGE Composite/Alu H8 Composite/Alu H8 tool life 1200 holes all Diameter are within the specification 800 holes all burr results are within the specification Diameter is always within the specification, even if the tool life end The performance is fail save. Even when the tool life is finished the quality of the hole is good
51 RESULTS - DRILLING ONE SHOT COMPOSITE / TITAN - FUSELAGE Composite/Titanium H9 120 holes all Diameter are within the specification 120 holes all burr results are within the specification Diameter is always within the specification. Tool life is indicated due to the size of the burr. Tool life is not reached so far. Result from customer Spirit (Wichita) told us 650 hole with one tool on robot application. The performance is fail save. Even when the tool life is finished the quality of the hole is good
52 DRILLING OF AEROSPACE COMPOSITES/METAL STACKS CUTTING PARAMETERS Dc Z Vc RPM Fz Fz eff Table feed Ap Ae Dust Q-MRR Diameter of cutter Number of flutes cutting speed Spindle speed feed per teeth effective feed Table feed cutting depth cutting width Dust Volume
53 WENN ZWISCHEN IHNEN UND UNS MEHR ENTSTEHT DAS IST DER MAPAL EFFEKT Fail Save Solutions
54 MD-PS-AIR E-A
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