Aerospace – Engine Case
An aircraft engine is a device that sprays fuel into air compressed by turbines to facilitate continuous combustion and generate high-temperature gases. In manufacturing critical components like combustion cases, choosing the right tools tailored to the machining process is essential. The ability to accurately and efficiently machine complex shapes is crucial for achieving high functionality and cost reduction. Tungaloy’s proprietary technology provides effective solutions, including optimal cutting tool shapes and accumulated expertise, even for machining complex-shaped parts made from materials that are difficult to cut and cause rapid tool wear.
Tooling concepts
- Improves productivity and prevents chattering on thin wall parts
- Application of low cutting force tools to achieve high speed and high D.O.C
- In order to maximize the performance of the 5-axis machine, apply multi-functional tools and machining methods such as ramping and contouring
Featured process
Process 1: OD Rough turning
Benefits
- The TS300 grade is a ceramic grade known for its high toughness and can be applied at a higher D.O.C. even within the ceramic grade category
- By reducing the number of machining paths, the effects of work hardening of materials are reduced and the tool life is extended
- TungCap tooling significantly reduces machine downtime
- TungCap, with two face contacts ensures high tool rigidity and contributes to improving the efficiency of rough machining
- Sialon ceramic with excellent wear resistance and fracture resistance
- The solution for high-speed and high-efficiency machining of heat-resistant alloys
Process 2: OD Finish turning
Benefits
- Applying grooving tools to profiling turning operations allows for machining with a single tool, achieving tool consolidation and reducing machining time.
- External turning with grooving tools induces a pseudo-small approach angle caused by holder flexure, resembling a high-feed cutting edge. This high-feed cutting edge proves effective in prolonging tool life during difficult-to-cut materials machining.
- Multi-functional system for diverse grooving needs
Process 3: Rough milling
Benefits
- Ideal for machining difficult-to-cut materials due to its 4-corner positive insert
- The UER cutting edge design, with a 7° approach angle and a low cutting angle specification, is effective for extending the tool life in Inconel machining
- High rake angle reduces cutting force
- Low cutting force and high rigid insert clamping helps to achieve stable milling processes
Process 4: Thread milling
Benefits
- Apply thread milling as an alternative to tap machining, which often encounters problems due to chip entanglement and clogging
- Suppresses troubles caused by chips, achieving stable thread machining
MTECZ-UN
- Ideal for threading process with a coating film that maintains a sharp cutting edge.
- Maintains a sharp cutting edge and ensures stable screw accuracy.
Process 5: Holemaking with Chamfering
Benefits
- Combined drilling and with chamfering using a DrillMeister head
- Reduced the process time by performing drilling and chamfering process at the same time
DMP Drill Head
- Smooth radius edge honing provides low cutting force
- Latest AH9130 grade ensures long tool life
Process 6: Back Chamfering
Benefits
- A specialized tool for back chamfering in holes where machining direction is restricted
- By using low-resistance inserts, chatter is suppressed, improving the quality of the chamfered surfaces
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