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

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Presentation on theme: "The Influence of High Pressure Coolant on Process Optimization in Heat Resistant Super Alloys (HRSA) Sean Holt Aerospace Application Manager Sandvik Coromant."— Presentation transcript:

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

2 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 2

3 3 The History of High Pressure Coolant (HPC) Multi-task Machining center Turning center Pressure bar (psi) 500 (7250) 100 (1450) Ccoupling for UHPC VTL Standard coupling

4 4 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

5 5 Pressure (p) Force per unit area – Pascal = N/m 2 – 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) High Pressure Coolant Definitions KkKk ( ) (w)(w)

6 6 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

7 HPC – Machining Requirements

8 8 HPC – System requirements Pump/machine –Pressure –Volume/flow rate –Filter Tool –Nozzle diameter –Number of nozzles –Jet flow –Jet direction

9 9 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 w 1 w2w2

10 10 Flow expressed in m 3 /s C D Nozzle efficiency - 80% 20 to 300 bars ( psi) - 70%300 to 1000 bars ( psi) nNumber of nozzles dNozzle diameter (m) pPressure (Pa)- 1 bar ( Pa) - 1 psi (6895 Pa) Fluid density - for water and cutting fluids the density is ~ 1000 kg/m 3 HPC – System requirements Flow requirement The larger the outlet area the greater the flow required to deliver a given pressure

11 HPC – Machining HRSAs

12 12 Coromant Capto ® Normal coolant inlet Hydraulic wedge lifts the chip Reduces temperature Improves chip control High precision jet nozzles Pre-defined target areas on the insert face HPC – Turning applications Precision is the power

13 13 With CoroTurn ® HP 70 bars (1160 psi) – Metal removal +50 at same speed – Cutting speed +20% with same total metal removal HPC – Turning applications Inconel 718 (46HRC) -Total material removed (TMR) Insertapap fnfn CNMX 1204A2-SM S05F2.5 mm0.3 mm/rev CNMX 43A2-SM S05F0.1 inch0.012 inch/rev Total material – Q (cm 3 ) Surface cutting speed – V c (m/min), ft/min

14 14 Normal Pressure80 bar (1160 psi) HPC – Turning applications Inconel 718 (46HRC) - Chip control Insertvcvc CNGG SGF m/min CNGG 432-SGF sfm Feed f n (mm/rev) Cutting depth a p (mm) Feed f n (mm/rev) Cutting depth a p (mm)

15 15 CoroTurn ® HP normal pressure CoroTurn ® HP 80 bars, 1160 psi HPC – Turning applications Inconel 718 (46HRC) - Demonstration Insertapap fnfn CNGG SGF mm0.15 mm/rev CNGG 432-SGF inch0.006 inch/rev

16 HPC – Machining in the Future

17 17 UHPC – Turning applications The basic concept of the technique 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) Coolant inlet UHPCHPC

18 18 UHPC bar (3300 psi) – 3 mins Normal coolant – 3 mins UHPC bar (4350 psi) UHPC – Turning applications Effect on Inconel 718 UHPC bar (2200 psi)

19 Summary 19 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

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