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Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Exploitable results
A286 and INCONEL 718 are materials that, due to their high Ni content and heat resistance, are very difficult to machine, and this results in the high cost of parts manufactured with these materials. The results of this process will open the way for more cost-effective production processes for aerospace parts. TiAl is a good candidate material for future aerospace applications, due to its low weight and good resistance at high temperatures. However, its low machinability (10 % of that of Ni alloys) makes the production costs very high for many applications. A reduction of the TiAl intermetallic machining cost will open up the possibility of the design and application of new parts.
The partners of this project want to develop new machining tools, nanocomposite coatings and machining processes to address the following industrial objectives:
- tool life increase
- reduction of production costs
- increase of machining productivity (more advanced cutting parameters)
- optimal coolant utilization
- improvement of finishing quality.
All these objectives are related to the machining processes of heat resistant alloys used in aerospace applications. The selection of materials will be focused on the following:
- Fe-Ni alloys: A286
- Ni based materials: INCONEL 718, IN 100
- intermetallics: g-TiAl
- reduction by more than 50 % of the process costs where the tools have been coated and new cutting technologies have been applied
- increase by more than 100 % in machining efficiency of milling Fe-Ni, Ni alloys and g-TiAl
- increase by more than 100 % in machining efficiency of turning Fe-Ni, Ni alloys and g-TiAl
- increase by more than 50 % in machining efficiency of drilling Fe-Ni, Ni alloys and g-TiAl.
The term 'machining efficiency' is directly related to production costs, and takes into account parameters such as tool life, machining speed and tool cost.
The following improvements have been presented:
Design of cutting tools:
- Tool geometry: Radial rake angle, Helix angle, Primary clearance angle, Primary clearance land width, Point angle (drills), Point clearance angle (drills)
- Edge preparation: Increased cutting edge radius, Improved surface finish, Improved coating adhesion, Less microchipping at tool edges
- Carbide grad
- Tool parameters: Variation of radial rake angle, Variation of helix angle.
Tool coating (nano-composite): Composite of a high strength amorphous phase as matrix(a-Si3N4) and hard transition metal-nitride nanocrystals, Nanocomposite PVD-coatings, Nanocrystalline grains (Ti1-xAlxN or Cr1-xAlxN) embedded into an amorphous matrix (SiNy), Monolayer or multilayer coatings, Extremely high hardness (42-45 GPa) combined with very high toughness, Extremely high heat resistance (up to 1200°C)
High Pressure Cooling (150 bar)
Achieved benefits:
Increase machining efficiency: Tool cost, Coating cost, Tool refurbishment, Machine cost, Tool life (from chipping catastrophic to continuous wear controllable), Machining conditions.
The benefits are related to the increase in productivity, i.e. reduction of machining time with an additional contribution in tool consumption saving. This will be achieved by the new developments allowing for more advanced machining conditions (tougher and quicker) and controlled tool wear development.
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