Presentation on theme: "High Pressure Coolant DVD"— Presentation transcript:
1 High Pressure Coolant DVD The Influence of High Pressure Coolant on Process Optimization in Heat Resistant Super Alloys (HRSA)High Pressure Coolant DVDSean HoltAerospace Application ManagerSandvik Coromant
2 High Pressure Coolant DVD AgendaIntroduction and history of High PressureChallenges in MachiningOperational differencesHPC System requirements, benefits & considerationsHRSA machining results & difference with other materialsFuture trends & directionsIntroduction & 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?
3 High Pressure Coolant DVD The History of High Pressure Coolant (HPC)500 (7250)Ccoupling for UHPC100 (1450)VTLPressure bar (psi)Multi-taskMachining centerTurning centerStandard coupling19841990199620072012
4 High Pressure Coolant Definitions High Pressure Coolant DVDHigh Pressure Coolant DefinitionsHigh Pressure Coolant (HPC) up to 80 bar (1160 psi)Standard option on most machinesTurning centersMachining centersMulti-task machinesStandard Coromant Capto® couplingStandard Sandvik Coromant tools availableUltra High Pressure Coolant (UHPC) over 80 bar (1160 psi )Standard option for a few machine manufacturersLimited to VTLsCoromant Capto® coupling for UHPCTool holders only as special
5 High Pressure Coolant Definitions High Pressure Coolant DVDHigh Pressure Coolant DefinitionsPressure (p) Force per unit areaPascal = N/m2Bar = 0.1 MPa (14.5 psi)Flow rate () Volume displaced per time unitliter/min (gallons/min)Velocity (w) Speed fluid moves through a tubem/sec (ft/sec)Kk()(w)HPC definitionsPressure 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 MPapsi (pounds per square inch) where 1 bar = 14.5 psiFlow rate () is the volume of coolant displaced per time unit Measured in :Liters or gallons per minuteFluid velocity (w) is the speed at which the fluid moves through a tubeMeasured in :Meters or feet per second
6 High Pressure Coolant Challenges in machining High Pressure Coolant DVDHigh Pressure Coolant Challenges in machiningOperation differences:Turning – continuous single pointCutting temperatureChip controlMilling – interrupted multiple teethChip formationCutter positioningRe-cutting of chips – unsecure or short tool lifeDrilling – continuous multiple teethVarying cutting temperaturehot peripherytough centerChip control and evacuation through fluteThe 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
8 HPC – System requirements Pump/machinePressureVolume/flow rateFilterToolNozzle diameterNumber of nozzlesJet flowJet directionSystem requirementsToday, 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.
9 HPC – System requirements Principles Reducing the area increases the velocitySmaller outlet reduces the pressure and flow rate requirements to achieve a high velocity jetFlow velocity w1Principle of HPCThe 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 w1w2
10 HPC – System requirements Flow requirement High Pressure Coolant DVDHPC – System requirements Flow requirement Flow expressed in m3/sCD Nozzle efficiency- 80% 20 to 300 bars ( psi)- 70% 300 to 1000 bars ( psi)n Number of nozzlesd Nozzle diameter (m)p Pressure (Pa) - 1 bar ( Pa) psi (6895 Pa) Fluid density - for water and cutting fluids the density is ~ 1000 kg/m3The larger the outlet area the greater the flow required to deliver a given pressure
12 HPC – Turning applications Precision is the power High Pressure Coolant DVDHPC – Turning applications Precision is the powerHydraulic wedge lifts the chipReduces temperatureImproves chip controlCoromant Capto® Normal coolant inletThe 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 nozzlesPre-defined target areas on the insert face
13 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/minInsertapfnCNMX 1204A2-SM S05F2.5 mm0.3 mm/revCNMX 43A2-SM S05F0.1 inch0.012 inch/revWith CoroTurn® HP 70 bars (1160 psi)Metal removal +50 at same speedCutting speed +20% with same total metal removalLab tests show thatat the same cutting data: + 50% increase in tool lifecutting speed can be increased 20% (50 to 60m/min) and the HP can remove more material than normal pressure at 50m/minThis 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?
17 UHPC – Turning applications The basic concept of the technique High Pressure Coolant DVDUHPC – Turning applications The basic concept of the techniqueUHPCHPCCoolant inletThe 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® couplingUHPC blanks - prepared with four sealing seatsbar ( psi)HPC tool – internal coolant supply through Coromant Capto ® polygon80 bar (1160 psi)
18 High Pressure Coolant DVD UHPC – Turning applicationsEffect on Inconel 718Normal coolant – 3 minsUHPC bar (3300 psi) – 3 minsUHPC bar (2200 psi)UHPC bar (4350 psi)
19 Summary HPC has seen significant improvements in the last few years New technologies & methods have made machining in HRSAs more efficientBenefits of using HPC in HRSA machining:Improves chip controlImproves tool lifeImproves cutting speeds
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