Safe-Lock™: Application in the aerospace industry at a large aircraft manufacturer in the USA

Problem:

  • Low metal removal rate (especially for roughing)
  • Low cutting tool life
  • Expensive scrap at titanium and aluminium workpieces
  • All tests with different systems failed: Milling Chucks, Press-Fit Chucks, Hydraulic Chucks or reinforced shrink fit chucks could not prevent cutting tool pull-out, despite high clamping forces
  • As a result they only used Whistle Notch / Weldon

 

Target:

  • Needed to increase metal removal rate – especially for roughing
  • Wanted to increase cutting tool life
  • Increase of process reliability to avoid expensive scrap

Application: Roughing Titanium

<strong>Workpiece:</strong> Critical airplane component made of Ti6Al4V, a titanium alloy
<strong>Machine:</strong> Vertical portal milling machine
<strong>Machine tool:</strong> HSK-A100
<strong>Tool holder:</strong> Shrink Fit Chuck HAIMER Safe-Lock<sup>TM</sup>, Ø 32 mm, length 120 mm
<strong>Roughing, Fine machining:</strong> one and the same coated solid carbide tool, effective cutting length of 83 mm

Result:

  • Cutting tool was securely held due to Safe-LockTM in all tests, no movement in the chuck during the entire machining process
  • No danger of the tool being pulled out of the chuck
  • Tool life more than doubled
  • During roughing and finishing operations no vibrations, and consequently no chatter marks – unlike the Weldon chuck
  • Significant productivity increases through the increase in material removal rates of 30%
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