# High Pressure Coolant DVD

## Presentation on theme: "High Pressure Coolant DVD"— Presentation transcript:

High Pressure Coolant DVD
The Influence of High Pressure Coolant on Process Optimization in Heat Resistant Super Alloys (HRSA) High Pressure Coolant DVD Sean Holt Aerospace Application Manager Sandvik Coromant

High Pressure Coolant DVD
Agenda Introduction and history of High Pressure Challenges in Machining Operational differences HPC System requirements, benefits & considerations HRSA machining results & difference with other materials Future trends & directions Introduction & history – Why did the industry go this way? What are the needs from manufacturing? Future trends & directions – What’s new – cyro, CO2, laser, oil mist versus coolant?

High Pressure Coolant DVD
The History of High Pressure Coolant (HPC) 500 (7250) Ccoupling for UHPC 100 (1450) VTL Pressure bar (psi) Multi-task Machining center Turning center Standard coupling 1984 1990 1996 2007 2012

High Pressure Coolant Definitions
High Pressure Coolant DVD High Pressure Coolant Definitions High Pressure Coolant (HPC) up to 80 bar (1160 psi) Standard option on most machines Turning centers Machining centers Multi-task machines Standard Coromant Capto® coupling Standard Sandvik Coromant tools available Ultra High Pressure Coolant (UHPC) over 80 bar (1160 psi ) Standard option for a few machine manufacturers Limited to VTLs Coromant Capto® coupling for UHPC Tool holders only as special

High Pressure Coolant Definitions
High Pressure Coolant DVD High Pressure Coolant Definitions Pressure (p) Force per unit area Pascal = N/m2 Bar = 0.1 MPa (14.5 psi) Flow rate () Volume displaced per time unit liter/min (gallons/min) Velocity (w) Speed fluid moves through a tube m/sec (ft/sec) Kk () (w) HPC definitions Pressure is force per area unit. Pressure (p) is used to describe the influences on fluid and gas behavior. Measured in : Pascal which is Newton per square meter (N/m2) Bar, where 1 bar = 0.1 MPa psi (pounds per square inch) where 1 bar = 14.5 psi Flow rate () is the volume of coolant displaced per time unit Measured in : Liters or gallons per minute Fluid velocity (w) is the speed at which the fluid moves through a tube Measured in : Meters or feet per second

High Pressure Coolant Challenges in machining
High Pressure Coolant DVD High Pressure Coolant Challenges in machining Operation differences: Turning – continuous single point Cutting temperature Chip control Milling – interrupted multiple teeth Chip formation Cutter positioning Re-cutting of chips – unsecure or short tool life Drilling – continuous multiple teeth Varying cutting temperature hot periphery tough center Chip control and evacuation through flute The challenges in turning: - Accurately sighting the nozzle for the het to hit the right place - Keeping a parallel, laminar jet to the cutting edge once leaving nozzle - Channeling of high volume, high pressure through all machine interfaces into the nozzle

HPC – Machining Requirements

HPC – System requirements
Pump/machine Pressure Volume/flow rate Filter Tool Nozzle diameter Number of nozzles Jet flow Jet direction System requirements Today, many CNC machines have coolant supplies at pressures of 70 to 100 bar as standard or option with ample tanks and pumps. This is sufficient to incorporate HPC, which makes a noticeable difference to performance and results on more commonly used machining centers, turning centers, vertical lathes and multi-task machines. Standard equipment is sufficient with easy channeling of coolant to where the jet is applied. Modular tooling is an essential basis also for HPC machining partly to ensure quick tool changes for minimizing machine stoppages, but also to help secure coolant connections and supply from the machine to cutting edge. The modular quick-change tooling system Coromant Capto came to be the platform for the Jetbreak development and is today the basis for CoroTurn HP, the new standard high-pressure-coolant tooling for turning. It is ideal as it is designed with internal coolant supply and also well suited as the means with which to supply coolant at high pressure. The main system requirements for adapting HPC successfully are : - pressure - volume and flow rate - tool nozzle size and type. Filtration of coolant is important to get rid of chips and abrasive particles– helps to provide wear on tools and machine parts - prolong the life of the equipment. A general recommendation is 5 to 25 microns filtration.

HPC – System requirements Principles
Reducing the area increases the velocity Smaller outlet reduces the pressure and flow rate requirements to achieve a high velocity jet Flow velocity w1 Principle of HPC The principle behind the application of high pressure tooling is that by reducing the area of the tube that the coolant has to pass through increases the velocity of the coolant. By using a smaller outlet (nozzle), a reduction is achieved on the coolant - passing through the tube at a certain constant velocity (w1) - that is to be delivered at a certain pressure and flow rate at the point that matters : the cutting edge (w2). Flow velocity w1 w2

HPC – System requirements Flow requirement
High Pressure Coolant DVD HPC – System requirements Flow requirement  Flow expressed in m3/s CD Nozzle efficiency - 80% 20 to 300 bars ( psi) - 70% 300 to 1000 bars ( psi) n Number of nozzles d Nozzle diameter (m) p Pressure (Pa) - 1 bar ( Pa) psi (6895 Pa)  Fluid density - for water and cutting fluids the density is ~ 1000 kg/m3 The larger the outlet area the greater the flow required to deliver a given pressure

HPC – Machining HRSAs

HPC – Turning applications Precision is the power
High Pressure Coolant DVD HPC – Turning applications Precision is the power Hydraulic wedge lifts the chip Reduces temperature Improves chip control Coromant Capto® Normal coolant inlet The coolant enters the tool through the normal coolant inlet and the Coromant Capto® coupling. No further installation required. The secret is the high precision jet nozzles positioned close to the insert cutting edge. The nozzles project a parallel, laminar jet to pre-defined target areas on the insert face edge. The coolant jets hit in between the top face of the insert and the chip and act like a hydraulic wedge to lift the chip. This shortens the contact length between the insert and the material to reduce cutting forces, lower the temperature and improve chip control. High precision jet nozzles Pre-defined target areas on the insert face

High Pressure Coolant DVD
HPC – Turning applications Inconel 718 (46HRC) -Total material removed (TMR) Total material – Q (cm3) Surface cutting speed – Vc (m/min), ft/min Insert ap fn CNMX 1204A2-SM S05F 2.5 mm 0.3 mm/rev CNMX 43A2-SM S05F 0.1 inch 0.012 inch/rev With CoroTurn® HP 70 bars (1160 psi) Metal removal +50 at same speed Cutting speed +20% with same total metal removal Lab tests show that at the same cutting data: + 50% increase in tool life cutting speed can be increased 20% (50 to 60m/min) and the HP can remove more material than normal pressure at 50m/min This benefit is only available with CoroTurn HP – without an optimized solution harnessing the coolant it would be just a high pressure shower –compare putting hand under a tap or a shower – where do you feel the force?

HPC – Turning applications Inconel 718 (46HRC) - Chip control
High Pressure Coolant DVD HPC – Turning applications Inconel 718 (46HRC) - Chip control Insert vc CNGG SGF1105 65 m/min CNGG 432-SGF 1105 213 sfm Normal Pressure 80 bar (1160 psi) Cutting depth ap (mm) Cutting depth ap (mm) 2.0 2.0 1.0 1.0 0.5 0.5 Feed fn (mm/rev) Feed fn (mm/rev) 0.25 0.25 0.15 0.2 0.25 0.15 0.2 0.25

HPC – Turning applications Inconel 718 (46HRC) - Demonstration
High Pressure Coolant DVD HPC – Turning applications Inconel 718 (46HRC) - Demonstration Insert ap fn CNGG SGF 1105 0.25 mm 0.15 mm/rev CNGG 432-SGF 1105 0.01 inch 0.006 inch/rev CoroTurn® HP normal pressure CoroTurn® HP 80 bars, 1160 psi

HPC – Machining in the Future

UHPC – Turning applications The basic concept of the technique
High Pressure Coolant DVD UHPC – Turning applications The basic concept of the technique UHPC HPC Coolant inlet The pictures illustrate the difference between the UHPC and HPC technique. In a UHPC tool, coolant is supplied externally into the Coromant Capto® coupling. UHPC blanks are prepared with four sealing seats, final design will determine if one or more will be drilled through for coolant supply. HPC has internal coolant supply through the Coromant Capto® polygon as a standard tool. UHPC tool - coolant supplied externally into the Coromant Capto® coupling UHPC blanks - prepared with four sealing seats bar ( psi) HPC tool – internal coolant supply through Coromant Capto ® polygon 80 bar (1160 psi)

High Pressure Coolant DVD
UHPC – Turning applications Effect on Inconel 718 Normal coolant – 3 mins UHPC bar (3300 psi) – 3 mins UHPC bar (2200 psi) UHPC bar (4350 psi)

Summary HPC has seen significant improvements in the last few years
New technologies & methods have made machining in HRSAs more efficient Benefits of using HPC in HRSA machining: Improves chip control Improves tool life Improves cutting speeds