The hardest there is

The aerospace industry is one of the most technically demanding fields existing – and components for aeroplane engines are among the most difficult to manufacture. Manufacturers can take advantage of the latest processing knowledge and the best possible tools when machining each component. Here are examples involving seven of the most important components of an aerospace engine.

Turbine disc

CoroTurn® SL70: Complex turning made easy

The flexible modular CoroTurn SL70 tooling system equipped with round inserts can be used for roughing and finishing of typical profiling and pocketing features. The SL70 system is perfect for turbine discs, which have complex features in difficult-to-manufacture alloys, often with profiled pockets and various difficult clearance requirements.

Fan disc

Get the right angle with CoroCut® angled inserts

Fan discs are made of titanium and have grooves and tulip grooves that must be machined. CoroCut angled inserts are formed to reach difficult-to-access grooves. They come in a variety of standard shapes so special tools are not needed.

Turbine casing

Ceramic turn milling for high-speed machining

When machining the turbine casing you have to remove large quantities of challenging materials (Inconel and Waspalloy, for example) through a rough milling process. Ceramic turn milling inserts offer opportunities to run 20 to 30 times the speed of carbide, although at lower feed rates, which results in high productivity gains

Fan casing

Stay cool with precision coolant

Successfully machining fan casings made of titanium requires keeping the cutting temperature low. The precision coolant systems from Sandvik Coromant are designed to hit the exact spot where the coolant is most usable, which results in good chip control, increased tool life and increased productivity.

Spool

Damped blades: When stability is all

One of the challenges in manufacturing a spool is its deep internal chambers. To manufacture these chambers, typically up to 150 millimetres deep, you need a long, slender tool. With the Coromant Capto® coupling system, damped blades offer a stable solution that minimizes vibration, allowing depth of cut to be four times greater than without damping.

Shaft

Silent Tools™: Quiet, please!

The length and the internal features of a shaft make it a perfect challenge for Silent Tools damped bars. The boring bar programme is available for up to 250 millimetres diameter and overhangs of up to 14 times the diameter, which is out of the parameters for conventional tools.

Blisk

Secure flexibility with CoroMill® Plura conical ball nose end mills

Flank milling (high axial depth of cut) is the fastest option possible when milling a component. The standard programme of conical ball nose end mills is specifically designed for this operation, offering excellent stability combined with reach.

Blisk

CoroMill® 316: Balanced productivity

In the manufacturing of blades on a disc or blisk, an optimal method for roughing is point milling. CoroMill 316 ball nose exchangeable cutting heads offers a great balance of productivity and economy.

For further information, please visit www.aeroknowledge.com.