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Machining with high pressure coolant has many advantages

Growing numbers of aerospace manufacturers are discovering the benefits of high pressure coolant (HPC), a machining technology that provides a genuine boost to productivity and results.

According to cutting tool and tooling systems specialist, Sandvik Coromant, which offers an extensive product range in this technology area, HPC can provide particular benefits when machining highly challenging aerospace materials, such as heat resistant super alloys (HRSAs) and titanium. The advantages of HPC include: greater machining security; better consistency; fewer machine stoppages; enhanced component quality; and shorter cycle times.

HPC is an effect produced by a combination of pressure, coolant flow rate and coolant outlet size. The good news is that most modern CNC machines have enough in-built capability to harness HPC with minimal, if any modification, ensuring rapid payback on HPC system components.

Sandvik Coromant offers a very comprehensive HPC product assortment, consisting of both standard products and engineered solutions to suit almost any conceivable application. CoroTurn® HP, for example, is a pioneering HPC system combined with the ultra-secure Coromant Capto® coupling for external and internal turning of especially demanding materials. The toolholder is equipped with two or three nozzles positioned and directed depending upon the tool type and application.

The heat is on

The high temperatures generated when machining aerospace materials such as titanium and HRSAs are due mainly to their strength and poor thermal conductivity. Heat is concentrated because of the highly sheared chips that form as a result of the short contact length between chip and rake face (typically only half that of steel). Using HPC to cool the machining zone is an easily-applied means with which to minimize tool wear, prolong tool life and provide the potential for higher cutting speeds.

Applications like internal turning invite particular challenges, such as generating suitable chips and enabling effective evacuation. Here, a number of CoroTurn HP solutions can help optimize operations. For instance, CoroTurn SL 32 and 40 boring bars with a round serrated lock coupling between boring bar and cutting head provide HPC machining for a large range of internal turning tasks, while Silent Tools dampening provides reliable boring when tool overhangs are more than 10 times the diameter. Similarly, the CoroTurn SL 70 concept is offered for grooving, profiling and pocketing operations using HPC. Ultimately, the result is better chip control, higher speeds, greater metal removal rates, up to 50 per cent more tool life and enhanced potential for unmanned production.

HPC is an optimizer

HPC should not be seen as a means with which to overcome shortcomings due to other application failures such as unsuitable insert, instability or incorrect cutting data. HPC is an optimizer when operations are established correctly. If required, Sandvik Coromant's team of aerospace machining experts will be pleased to help resolve any troublesome issues as part of their total package solution offer.

Just as high pressure can turn coal into diamonds, HPC can help turn aerospace machining operations into a goldmine. Sandvik Coromant says that HPC can be applied to external and internal turning, milling and drilling through its CoroTurn® HP, CoroMill® and CoroDrill® concepts.

Mini-catalogue

To help introduce HPC to machine shops, Sandvik Coromant has produced a new 48-page catalogue (reference code C-1040:091) that explains the benefits of HPC and what it can contribute to machining operations. Application areas, materials, pressures and jet effects are all explained in detail, along with a multitude of clearly defined tooling solutions. Easy-to-use ordering codes make the new catalogue a true machinist's friend, where all information relating to HPC is accessible from a single resource.

Press release issued by Sandvik Coromant on February 21, 2011

 

 Contact details from our directory:
Sandvik Coromant Cutting Tools

 

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