Taking Machining to Greater Heights

TaeguTec’s machining solutions help an engine part maker supplying to aerospace

engineering giants improve productivity and cycle time in a rough-milling- followed-by-finish-milling application involving a high-temperature alloy

The Indian aerospace industry has seen a much-desired boost in recent times, thanks to policy reforms including increased FDI investment attractiveness, as well as better access to finance and technology transfer. The ‘Make in India’ efforts have induced a spike
in demand from industries
like aerospace and defence,

resulting in gradual redistributing of the manufacturing pie to expand beyond automotive manufacturing.

While public-sector units have hitherto been the mainstay of the Indian aerospace industry, the gradual easing of government control in this space has given way to private players – global majors and small indigenous manufacturers – with successful public-private partnership outings. Now the challenges in aerospace manufacturing, per se, are very different from those arising in the automotive and auto parts set-ups, due to materials and volumes of manufacturing.

Materials, a challenge in aerospace

In terms of materials, aluminum – what was once the staple of aerospace industry – is long passé now. While paneling and interiors utilize light-weight carbon fiber reinforced polymers (CFRPs) and honeycomb materials, the critical engine parts and components are pushing towards lower weight and higher temperature resistance for better flight economics. Materials like heat resistant super alloys (HRSAs), including titanium alloys and nickel alloys, are much in demand, but machinability-wise, they present a whole set
of challenges.

 At one such aerospace customer – an engine part maker supplying to aerospace engineering giants – the challenge was to improve productivity and cycle time in a roughing-followed-by-finishing application involving a high-temperature alloy. A concentration of Ni greater than 50 percent renders the material extremely difficult to machine. The existing set of tools in the shopfloor were mostly Solid Carbide that are increasingly being outperformed by indexable tools. Solid Carbide tools are a high-maintenance set insofar as the frequent regrinding requirements go, not to mention the environmental disservice relating to high carbide consumption.

Roughing solution

TaeguTec’s high-feed solution Chase2Feed BLMP 06 was considered and it resulted in the benefit of 2 extra corners over the competition (productivity improvement by 17 percent), in addition to 31 percent reduction in CPC. The clamping rigidity was also much superior to that of the competition wherein the insert screws were getting damaged frequently.

Finishing solution

The Chase2Mill family came to the rescue in Finishing operations, with the compact four corners double sided 4NKT 06 inserts. The advantage of 4 corners was able to perform at 58 percent reduced CPC, while improving life per corner by
43 percent.

Source: TaeguTec India Pvt Ltd

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