Ideco, October 27th 2011

Technology For Titanium Machining

Prof. Dr.-Ing. E. Abele Dipl.-Wirtsch.-Ing. R. Hlscher

PTW Research Groups

Technology

Machine tools and components

Machining

Focus:
Mechanical Production Machine Tool Industry Batch Production

Production management

Sustainable production

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 1

PTWs Test Bay

Machines 7 3-axis HSC-milling machines 6 3-axis machining center 5 5-axis machining center 1 5-axos Micro machining center 4 CNC lathes 3 robots with motor spindle 1 DLMS-system (EOSINT270) Test benches test bench for motor spindles test bench for linear drives centrifugal force test rig tool balancer 3D dynamometer Measuring devices (selection) CMM (Leitz PMM 864, Quindos7) 3D scanner (GFM) microscopes (Alicona, Hitec) perthometer (Mahr) cutting forces measur. (Kistler)
Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 2

Impressions of Developments from the last 15 years at PTW

2001

2008 2006

European High Speed Machining Award

Multi-technology oriented reconfigurable machine tool

Tool security for HSC-Tools and high quality

1996

2001
1996

2004

2006
2004

2008

2008

2010

First 3D-HSCMilling Machine

High-Speed Cutting with Industrial robot

2008

2010

HSC-Titanium

Titanium Cutting
*founded in year 1894

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 3

CFRP Ratio and Material Mix in Aircrafts

Fraction of structural weight in %

60 %

50 %

tomorrow
40 %

Airbus Titanium Aluminium Composites

A320 ca. 5 % ca. 70 % ca. 15 %

today

A350 20 % 20 % 55 %

30 %

20 %

10 %

1986 - A320

2012 - A350

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 4

Titanium is the better partner for CFRP (than Aluminium)

1
0

Different thermal expansion coefficients 1 Volt electrical potential galvanic corrosion

Isolation needed F F

CFRP Aluminium

Volt

lower material properties tensile strength 620 MPa fracture toughness 35MPa m1/2 Welds difficult to realize similar expansion coefficients 0,2 Volt electrical potential no galvanic corrosion no isolation needed higher material properties tensile strength 900 MPa fracture toughness 77 MPa m1/2 Welds possible

1
2
0
F F

CFRP Titanium

Volt

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 5

787 Dreamliner: Change from AL to Titanium structural elements (Seat carrier beam)

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 6

source: Boeing

Titanium Alloys: Impact on Machining

Today's typical buy-to-fly ratios:

Example 787 - Machining:

source: Boeing

Plate: Extrusions: Die Forged:

30:1 12:1 8:1

Raw Material:

90,718 kg

Fly Away:

11,340 kg buy to fly of 8:1

10x
Machining time increases cause of low material removal rate!
(in relation to aluminium)

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 7

Technical/Innovative Development with the help of Metal Removal Rate Comparison

Aluminium Processunderstanding HSC Machining Improved Spindles and Machine Tools HPC Cutting Tool Development

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 8

Difficulties in Machining Titanium

Properties of Titanium, Steel and Aluminium

Properties Specific mass (g/cm3) Youngs Modulus (GPa) Tensile strength Rm (MPa) Elastic Limit Rp0,2 (MPa) Elongation A5 (%) Hardness (HB) Heat Capacity cp (J/kgK) Heat Conductivity (W/mK) Ti-6Al-4V 4,43 110 900-1180 830-1030 8-15 320 520 7,5 Ck45 7,78 210 630 390 14-17 170 486 51,9 AL 7075 2,8 72 180-560 100-505 3-6 55-163 862 115-140

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 9

Difficulties in Machining Titanium

Properties of Titanium, Steel and Aluminium

Properties Specific mass (g/cm3) Youngs Modulus (GPa) Tensile strength Rm (MPa) Elastic Limit Rp0,2 (MPa) Elongation A5 (%) Hardness (HB) Heat Capacity cp (J/kgK) Heat Conductivity (W/mK) Ti-6Al-4V 4,43 110 900-1180 830-1030 8-15 320 520 7,5 Ck45 7,78 210 630 390 14-17 170 486 51,9 AL 7075 2,8 72 180-560 100-505 3-6 55-163 862 115-140

Selected difficulties in machining Titanium

high thermal loads of the cutting edge due to very low heat removal with the chips highest compression loads of the cutting edge cause of low area of contact in between chip and edge high alternating loads due to the lamellar chipping caused by the high strength under high temperatures

breakage of the tool edge as a tool failure because of high cutting forces and self excited chatter vibrations high wear rate due to diffusion because of reactivity of work piece material which leads to weakening of the tool

Low productivity as a results of titanium alloy properties

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 10

Requirements for Machine Tool

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 11

Requirements for tool holder

Clamping force too low at hydraulic expansion chuck

hydraulic expansion chuck

ap = 16mm

ae = 8mm + 7mm ap
Increasing the clamping force through massive shrinking chuck
Massive shrinking chuck

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 12

Main Problem areas to overcome. Identification of success factors

Problem areas:
Heat accumulation at the cutting edge
small heat transfer with chips (Titanium max.25%, Alu 75%)

Success factors

Tool
- Optimization of the cutting geometry - Cutting materials and coatings - High feed tools (inserts)

No reduction of tensile strength

low heat transfer to cutting material

Cooling
- Coolant pressure increase - Cooling lubricant with Ester-Oil - CO2 cooling (in future with MQL)

Milling strategy
- Machining Strategy (roll-in) - Trochoid Strategy - Preheating of Titanium alloy

Cooling strategies as a point of optimization

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 13

Some classical optimisation strategies fail (full cut)

Clasical grinding High prssure Water-jet preparation

R = 5,41 m
Lt in [min]

R = 21,55 m

Tool life in feed direction

Tool life in feed direction

Lf Standard Tool

Lt

Lf

Lt

Edge preparation bring a higher cutting edge rounding (from 5 m to 22 m) and a less tool life For titanium machining are sharp edges necessary Lf Lt

Lf in [m]

Cutting edges praperation

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 14

Different Coatings for Carbide Tools

Common advantages of coatings: smooth surface reduction of friction heat resistance heat protection of cutting material hardness resistance protection against abrasion

AlTiN based milling tool

Vergleich

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 15

Different Coatings for Carbide Tools

Common advantages of coatings: smooth surface reduction of friction heat resistance heat protection of cutting material hardness resistance protection against abrasion

AlTiN based milling tool

Used coating-characteristics

1
(confidential) TiB2 Vergleich Monolayer silvergrey 4.000 900

Coatings

Manufacturer Name coating material coating layer color Micro-Hardness [HV0,05] Max. operational temperature [C]

(confidential) AlTiN based Monolayer gray 3.400 1.000

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 16

Comparison of tool life for coated and uncoated carbide tools especially with Ester-Oil cooling
Abord criterium: 300 m / WSP Mapal ae=1,5, ap=5

vc=50min-1

fz=0,3mm

150 m

100 m

VBmax~50 m

50 m Lf in [m]

0m

93 m

<150 m > 150 m

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 17

> 150 m

Comparison of tool life for coated and uncoated carbide tools especially with Ester-Oil cooling
Abord criterium: 300 m / WSP Mapal ae=1,5, ap=5

vc=50min-1

fz=0,3mm

vc=70min-1

fz=0,3mm

150 m

150 m

100 m

VBmax~50 m

100 m

VBmax~100 m

50 m Lf in [m]

93 m

<150 m > 150 m

> 150 m

50 m 44 m

> 150 m

0m

0m

Coatings have a significant effect on the tools life time (*especially with Ester-Oil cooling) A smooth covering shall reduce friction and heat influence
Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 18

63 m

Comparison of tool life for coated and uncoated carbide tools especially with Ester-Oil cooling
Abord criterium: 300 m / WSP Mapal ae=1,5, ap=5

vc=50min-1

fz=0,3mm

vc=70min-1

fz=0,3mm

vc=100 min-1 fz=0,2mm

150 m

150 m

150 m

100 m

VBmax~50 m

100 m

VBmax~100 m

100 m
VBmax=300 m

50 m Lf in [m]

93 m

<150 m > 150 m

> 150 m

50 m 44 m

> 150 m

50 m 63 m 33 m 63 m 76 m

0m

0m

0m

Coatings have a significant effect on the tools life time (*especially with Ester-Oil cooling) A smooth covering shall reduce friction and heat influence
Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 19

Identification of success factors

Problems of chip removal

Heat accumulation at the cutting edge
small heat transfer chips (max.25%, Alu 75%)

Points for optimization Tool

- Optimization of the cutting geometry - Cutting materials and coatings - High feed tools (inserts)

No reduction of tensile strength, e.g. through heat transfer

Cooling
- Coolant pressure increase - Cooling lubricant with Ester-Oil - CO2 cooling (in future with MQL)

Milling strategy
- Machining Strategy (roll-in) - Trochoid Strategy - Preheating of Titanium alloy

Colling stategies as a point of optimization

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 20

Cooling Strategies

Waterbased Emulsion

Synthetic Ester-Oil

CO2-Cooling
vc = 200 m/min, fz = 0,1mm,ae=1,5, ap=5 vc=200m/min is possible with high surface quality finishing

105 bar

112 bar 110 bar

High Pressure Volumen Cooling

Internal C.: 110 bar with 85 l/min External C.: 10bar with 50 l/min
source: Rolls-Royce (Germany)

High cooling rate through Water but low impact to friction reduction

Reducing the heat accmulation by reducing friction

Application of cooling at the cutting edge of -78 C.

Different Solutions to reduce the heat influence at the cutting edge

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 21

Variation of Lubrication medium

synthetic Ester-Oil
tool life Lf [min]
ICL 110bar ECL 15bar coated

50 0%

to

ol -li fe

ICL 110bar ECL 15bar

waterbased emulsion
ICL 110bar ICL 120bar ICL 120bar ECL 15bar ECL 15bar coated

ICL 60bar ICL 110bar

Cooling Strategy

ICL : internal cooling lubrication ECL: external cooling lubrication

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 22

Identification of success factors

Problems of chip removal

Heat accumulation at the cutting edge
small heat transfer in chips (max.25%)

Points for optimization Tool

- Optimization of the cutting geometry - Cutting materials and coatings - High feed tools (inserts)

No reduction of tensile strength, etc. through heat transfer

Cooling
- Coolant pressure increase - Cooling lubricant with Ester-Oil - CO2 cooling (future with MQL)

Milling strategy
- Machining Strategy (roll-in) - Trochoid Strategy - Preheating of Titanium alloy

Answer to the heat problem in the cutting zone is one key factor for higher productivity
Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 23

Milling Strategy

Up-cut milling

Direct milling

Which milling strategy is preferable?

High pressure loads on the cutting edge can be reduced by direct milling

Quelle: Eigene Darstellung Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 24

Milling Strategy

Direct milling

Roll-in milling Strategy

High pressure loads on the cutting edge

With the roll-in milling strategy the pressure are allways small on the cutting edge

Through roll-in Milling Strategy tool life is up to 50-200% longer

Quelle: Eigene Darstellung Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 25

Conventional and Trochoidal Machining

Conventional Machining (2 cuts)
front view DT Tool plan view

Trochoidal Maschining (1 cut)

front view plan view

nut in one cut 1. full cut

vff v ap ap b b vf,zir vf,zir vf,lin vf,lin ae,max ae,max

ap

2. cut
ae work piece

vc= 60 U/min fz = 0,5 mm 1.Cut: ae = DT 2.Cut: ae = DT/2

vc = 60 U/min fz,max = 2 mm vf,zir = 3000 mm/min

Machining time 30 sec. High slot quality

Machining time 60 sec. Low slot quality

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 26

Conventional and Trochodial Machining

Boundary conditions: Conventional machining in two cuts:

DT

vc= 60 U/min fz = 0,5 mm 1.Cut: ae = DT 2.Cut: ae = DT/2

ap

Machining time 30 sec. High slot quality

b

Trochoidal milling in one cut:

Tool: SC-Cutter (z = 4, DT = 16 mm) Slot: b = 24 mm ap = 10 mm l = 250 mm

vc = 60 U/min fz,max = 2 mm vf,zir = 3000 mm/min

Machining time 60 sec. Low slot quality

Second cut for finishing nessesary

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 27

Conventional and Trochoidal Machining

Conventional Machining
Higher Qualtity and higher Produktivity

Trochoidal machining

Tool: SC-Cutter (z = 4, DT = 16 mm) Slot: b = 24 mm ap = 10 mm l = 250 mm

different circular speeds

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 28

Metal Removal Rate Comparison Aluminum and Titanium Alloys

Processunderstanding HSC Machining Improved Spindles and Machine Tools HPC Cutting Tool Development

Aluminium

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 29

Machining Strategies

HPC-Strategy

Challenge: High Speed machining Ti

HSC-Effect Strategy

y toda vc = moderate fz = up to 0,15 mm ae = 0,5D-full slot ap = max

w? orro Tom

long contact time

productivity because of high ae und fz

solid carbide 16 mm solid carbide 16 mm

Can HSC machining of titanium be economically? What preconditions must be created for a high speed machining of titanium?
Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 30

Machining Strategies

HPC-Strategy

Challenge: High Speed machining Ti

HSC-Effect Strategy

y toda vc = moderate fz = up to 0,15 mm ae = 0,5D-full slot ap = max

2 Fundamentals of HSC
1.Shear resistance (of the work piece) increase with cutting speed 2.Higher cutting speed causes higher temperatures (in the shear zone) and starts a thermaly reduction of shear resistance

w? orro vc = high Tom fz = moderate ae = 0,1D-full slot ap = max

long contact time

short contact time

productivity because of high ae und fz

solid carbide 16 mm

decreasing cutting forces

productivity because of high vc

solid carbide 16 mm

Can HSC machining of titanium be economically? What preconditions must be created for a high speed machining of titanium?
Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 31

Machinability of Aluminium and Titanium Alloys Influence of cutting speed

600 550

Cutting Force c [N] Schnittkraft F

500 450 400 350 300 250 0 1000

softening
Fc Ff Ft

2000

3000

4000 Cutting Speed

Schnittgeschwindigkeit vc [m/min] Cutting Speed vc

Milling of Al7075 at PTW continuous decrease of cutting forces

Milling of Ti-6Al-4V at PTW no significant decrease of cutting forces

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 32

Cutting Force

Titanium properties in reference to temperature

Stiffness

Tensile Strength

Shear Strengh

- 50% - 30%

- 50%

Influence of stiffness in reference to Temperature

Influence of tensile strengh in reference to Temperature

Influence of shear strengh in reference to Temperature

The material effects show machining process effects:

- decrease of cutting forces - wear of cutting tool decreases - tool life increases - chip formation improves

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 33

Posibilities for make use of HSC effect

Heating up the whole part usage of residual heat of forge heating in Oil heating using electric-furnace

Heating up only the cutting area Heating through friction Arc Load Microwaves Plasma Beam Laser Beam Induction

Two economic ways to heat up with Laser or Induction?

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 34

Possible ways of heat introduction to make use of HSC-Effect

Heating up the cutting area with Laser Pros: controllable placeable in the machining room information of heat conduction of titanium alloys Contra: high laser beam reflection at the surface
Source: IWB

Heating up the cutting area with Induction Pros: controllable (Power, Frequency, Inductor geometry, Inductor distance from material) placeable in the machining room (3-axis or 5-axis e.g. with a robot arm) information of heating depth and heat conduction of titanium alloys Challenge: lubrication solutions (electric flashover, danger of ignition), reliability

heating the material surface through heat vonduction

With Induction heating is possible to heat up material below the surface

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 35

Simulation of the preheating area and milling volume

Inductor output: 18.000 Hz 70.000 W maximum power

Inductor

Tool

Simulation allows to determine induction power und frequency

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 36

Experimental Setup

tool

Inner pipe MQL through the tool

inductor
Field coil

Effective direction protection Material

Inductor fix install in front of the tool Constant distance to the tool Line by line 3-axis direct milling of Ti-64

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 37

Comparison simulation and test

Influence of MQL-Cooling Thermalelements

ra me Ca IR-

Different temperatures results from the distance of inductor to surface

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 38

Results of preheating titanium

(vc = 350 m/min; fz = 0,1 mm, ap = 10 mm, ae = 1,5 mm) Tool lif Lf [min]

depth of cut

750 C

~ 500 C
700 C

15

tempering colours 10
ing ften o ial s

the rm al a bra sio n

ter ma g risin

25

100

200

300

400

500

600

700 [ Celsius]

Result: Optimum machining temperature for titanium around 500 C

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 39

Technical/Innovative Development with the help of Metal Removal Rate Comparison

Aluminium Processunderstanding HSC Machining Improved Spindles and Machine Tools HPC Cutting Tool Development

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 40

Congratulation, 25 years of sucess, cooperation and friendship

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 41

Thank you for your kind attention!

If you have any questions, do not hesitate to contact us
Prof. Dr.-Ing. E. Abele Institute of Production Management, Technology and Machine Tools Technische Universitt Darmstadt Petersenstr. 30 64287 Darmstadt, Germany Phone: +49 61 51 | 16 21 56 Fax: +49 61 51 | 16 33 56 e-mail: info@ptw.tu-darmstadt.de Internet: www.ptw.tu-darmstadt.de

Difficulties in Machining Titanium

Properties of Titanium, Steel and Aluminium

Properties Specific mass (g/cm3) Youngs Modulus (GPa) Tensile strength Rm (MPa) Elastic Limit Rp0,2 (MPa) Elongation A5 (%) Hardness (HB) Heat Capacity cp (J/kgK) Heat Conductivity (W/mK) Ti-6Al-4V 4,43 110 900-1180 830-1030 8-15 320 520 7,5 Ck45 7,78 210 630 390 14-17 170 486 51,9 AL 7075 2,8 72 180-560 100-505 3-6 55-163 862 115-140

Mechanical Engineering | Institute of Production Management, Technology and Machine Tools | Prof. Dr.-Ing. E. Abele 211027EA1| 43