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LMT Fette's tool completely solves the problem of forming "bird's nest"-like chips around the main shaft and the tool. This is why Volker Dittmar, the pilot production manager of Airbus, invited LMT experts to process the "Typhoon" fighter. The gas flange provides a solution.
The Varel plant in Germany produces complex structural components and tooling for all seven Airbus plants in Germany. The plant has 1,100 employees and produces more than 2.5 million parts per year, of which 19,000 different parts need to be milled in the factory and more than 4,000 parts for the Airbus A380.
Matthias Maack, development engineer at LMT, described the machining performance of the previously used integral shank end mills, which could not solve the problem of forming "bird's nest"-like chips, which affected the quality of the workpiece and the tool-to-machine power. The requirements are constantly improving. Maack said, “It is clear that we must work with Airbus engineers to develop a solid carbide tool that uses an smooth transition from the tool nose to the milling tooth to form an effective chip breaker.â€
In order to test and optimize the tool geometry, tool length, number of cutting teeth and geometry of the chip breaker, in addition to the simulation test on the LMT Fette CAD system, the cutting test was regularly performed on Airbus' Dörries Scharmann machine. The tool is optimized according to the material and machine conditions under actual production conditions. Maack added, “This is a bit like an F1 car. Although all the work is done outside the arena, the drivers have made a crucial contribution to the success of the entire team.â€
The Airline series, which is developed for aluminum machining and has a diameter of 25mm. It belongs to the LMT. It combines a special chip breaker and a spiral internal cooling channel. When machining, the geometry of the chip breaker can effectively break the chips, and the internal cooling channel delivers the emulsion coolant directly to the cutting zone, helping to prevent the chip from building a built-up edge. The tool has three helical cutting edges with a length of 22 mm and a cutting angle with a radius of 4 mm.
When processing the intake flange of the "Typhoon" fighter on the Dörries Scharmann ACM-H HPC machining center, the overall grooving is carried out with a depth of 25 mm and then linear machining at 17 mm/min (coolant pressure 25-50 bar) The cutting speed is maintained at 1492 m/min, the spindle speed is 19,000 rev/min, the feed rate is 9 m/min, the axial cutting edge is 13.5 mm, and the pitch is set to 0.16 mm.
Although tool development has been successful, Airbus and LMT engineers are still working to further improve and improve their milling performance. They are currently experimenting with the effect of reducing the radius of the arc of the cutting angle to 2 mm. If this improvement can be achieved, the radial depth of cut can be further increased. In addition, even with the introduction of the LMT Fette's micro-cutting edge geometry design, even better milling performance can be achieved.
The design of surfboard Traction Pad can be in one piece, two pieces, or three pieces basically. The standard the classical texture for traction pad would be diamond like texture, as it can provide the stronger grip among all of them.
The EVA color connect logo is made along with the pad itself. Unlike the PVC logo, it is also EVA material same as pad, and also shows with the texture. The design of this logo can not be too detailed and small, it needs to be larger and simpler so that we can use the different color EVA material to connect them.
LMT develops special tools for Airbus aircraft aluminum processing
LMT Fette has developed a solid carbide roughing tool with a fully integrated chip breaker for Airbus' manufacturing facility in Varel. When machining wrought aluminum alloys on the Dörries Scharmann five-axis machining center with this tool, it not only increases the axial feed rate by 50% (to 13.5 mm/rev), but also completely eliminates the drawbacks of previously existing tool performance instability. . In addition, this new tool reduces the spindle drive power requirements (even at material removal rates up to 3000 cm3/min) and provides 300 minutes of cutting time (without tool change during this time).
There are two ways to make the logo on the traction pad, one is PVC logo, the other one is EVA color connect logo.
PVC logo is a very simple idea, just make a PVC logo based on the design and insert it into the traction pad. One advantage of PVC logo is that it can be more detailed and complicated than the EVA color connect logo. And it can be repeatly used on other pads without any more setup tooling charge.