ONA has carried out a study to analyse a wire electro-erosion process (WEDM) as an alternative to the conventional machining (broaching) of fir-tree profiles in discs for the aerospace sector.

In its research, ONA compared the EDM process with more conventional machining like broaching and milling. As key points in the research, ONA compared parameters such as the surface integrity requirements, precision and processing time of fir-tree machining. The test involved cutting a turbine disc with the following characteristics: Inconel 718 material; 350 mm outside diameter; 28 fir-tree slot profiles; slot profiles at 30°; 82 mm thick; profile tolerance of 0.01 mm; and fir-tree radial and angular positioning tolerance of 0.08 mm.
On completion of the tests, the results proved it possible to obtain a recast layer thickness in the necessary range (around 5 µm) and with sufficient precision in the fir-tree profile within a tolerance of 0.01 mm using WEDM technology. These results were obtained following one roughing pass and two finishing passes (three-cut strategy).
In worse flushing conditions (open nozzles), the material removal rate for roughing was 110 mm2/min. In fact, for the strategy used in the research (one pass for roughing and two passes for finishing), material removal rate was 60 mm2/min. On the other hand, in good flushing conditions (closed nozzles), a slight improvement in the material removal rate was observed; in the roughing process alone, it reached over 400 mm2/min.
Following the research, ONA concludes that WEDM machining of turbine disc fir-tree profiles is an extremely valid alternative to compete with broaching as an industrial solution in the aerospace sector. State-of-the-art and increasingly powerful generators, and more advanced numerical controls, allow for the optimisation of machining time and the reduction of white layer thickness.
For further information www.onaedm.com

CADCAM software expert Radan has developed a partnership with IPG IRE-Polus – a Russian division of IPG Photonics – which manufactures fibre laser machines.

The partnership provides for the new LaserCube precision flat-bed laser to be sold with the Radprofile module for programming, along with a special post-processor and set of macros. Moscow-based IPG IRE-Polus recently hosted a special training seminar on the software, conducted by an engineer from Dreambird, Radan’s official Russian and CIS distributor.
For further information www.radan.com

Introduced to the UK two years ago, the TaeguTec Chase2Mill series of end mill tools is now being extended with the arrival of two additional insert designations.

Designed for ramp and slot milling applications, Chase2Mill is available in end mill, modular or face mill designations. Initially launched with a four-corner, double-sided 4NKT 06 insert range featuring a 90° entry angle that is suitable for high ramp-down applications, the 4NKT 06 has been expanded and a newly developed 4NHT insert series released.
TaeguTec’s 4NKT 06 corner R range insert has been extended (04R-20R) to meet the wider range of corner radius requirements demanded by today’s industry. Adding to the existing 8 and 16 mm radius inserts, the company has expanded the line to include a 4, 12 and 20 mm radius offering. The extended 4NKT 06 is available with TaeguTec’s ML and M geometry, and the TT8080 and TT9080 grades, which combine to improve cutting load, minimise built-up-edge and generate high surface finish, says the company.
In addition, the 4NHT 06 insert designation has also been launched with the 4NHT 06-ML, which is said to be characterised by its ability to generate low cutting loads and high surface finishes (credit to ground cutting edges that minimise built-up-edge).
Another release is the 4NHT 06-AL series of uncoated inserts for aluminium and non-ferrous cutting applications.
For further information www.taegutec.com

In order to boost the first stage roughing operation on newly cast aluminium parts for the automotive industry, Sandvik Coromant is introducing its M5Q90 tangential milling cutter.

Designed to complete ‘cubing’ (first machining of faces after casting) in a single operation without creating burrs, the new tool is fitted with PCD tangential inserts that provide a smooth and stable cutting action to lower power consumption and eliminate vibration. This concept ensures reliable performance, improved tool life, exceptional surface finish, high metal removal rate and an increased number of parts per insert.
“To enhance efficiency, our new M5Q90 tangential milling cutter features fully engineered cutter bodies matched with dedicated PCD insert geometries that feature a positive cutting angle to reduce cutting force and load on the machined component,” explains Emmanuel David, global automotive product manager.
M5Q90 cutter bodies are designed according to customer specifications and hence meet the requirements of high-productivity machining – the tool can operate in high-speed conditions in excess of 20,000 rpm. However, all cutter bodies offer the same design of tip seat, coolant channel, lead angle and rake angle. Inserts are always kept in stock.
Aluminium cylinder heads and engine blocks will be among the principal components to benefit, typically at automotive foundries or tier one/two suppliers. By way of example, the cubing operation on a cast cylinder head would involve machining the camshaft face, inlet/outlet face and combustion face. Typical cutting data using M5Q90 might include a speed of 2500 m/min and feed per teeth of 0.20 mm. Users also benefit from high-precision coolant channels that provide the option for either emulsion or MQL application.
For further information www.sandvik.coromant.com

Due to reasons that are well documented across Europe, manufacturers are faced with a shortage of skilled operators, especially in the sheet metal-working sector. Operating a press brake requires a good dose of talent, imagination and experience.

Even when the operator is trained and able to work autonomously, bending remains an activity that is sometimes tiring and tedious. This is particularly the case with regard to tooling, which often requires the handling of expensive and heavy tools. As batch sizes decrease, the time taken to position tools is often the same as the production time, reducing profitability.
For all these reasons, Gasparini has developed Agile, an automatic tool change system for press brakes up to 640 tonnes and 8 m capacity that offers high levels of versatility and customisation options.
Until now, automatic tool changers have focused on speed and the elimination of tooling errors. Agile is said to be a versatile automatic tool changer that allows bending to transform from a bottleneck to a production hub, releasing time and resources for other tasks.
Agile facilitates bending with frequent tooling, complex set-ups and expensive, heavy tools. The system helps in the production of special parts, both for the most experienced operators and those undergoing training. Handling both punches and tool adapters, Agile allows users to bend boxes measuring up to 290 mm tall, even with large size press brakes.
The work area can also be customised with bespoke opening, stroke and throat dimensions. Tooling can cover the entire machine length, with no limits on the length or number of stations. In addition, the machine can be equipped with front supports and bending aids, while the storage facility accommodates long tools, and supports hemming dies.
For further information www.gasparini.com