http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/RSS.ashxKYOCERA UNIMERCO PagesTue, 03 Apr 2012 15:56:11 +0200http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=1http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=1Tool solutions Focus segments for the aerospace industry2012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=2http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=2Our introdution OPTIMISED PRODUCTION KYOCERA UNIMERCO Tooling A/S – your full-service tooling partner Kyocera Unimerco offers a complete tooling programme for machining aerospace metals and fibre composites. as the choice of tool is always based on a cost-benefit assessment, the solution often includes standard, customised carbide and diamond tools. This allows you to get the best total solution from one source, thus reducing your supplier base. Norms and ECR – guarantee of identical tools, whether new or RE•NEW® all of our companies utilise integrated caD/cam for design and production. The solution is part of the guarantee of 100% identical design and production. all tools have been designed in accordance with our norms (a norm is an instruction that controls the geometry, measurement and manufacturing process). The norms are developed and maintained centrally and subsequently distributed to all companies in Kyocera Unimerco via our central server. For this specific purpose, the central programme database secures that all cnc-controlled machines in all our companies use the exact same machining data. all cnc machines are from the same manufacturer and are also calibrated to a master machine. Programmes are automatically deleted from each machine immediately after use. in addition, we have created an electronic drawing database which offers version management, search options and traceability. The results are short design times, high accuracy and repeatability and high-capacity utilisation resulting in fast deliveries. The benefit is that any tool will perform the same whether new or RE•NEW® guaranteeing you process reliability and high performance. High performance tooling solutions To machine a component at the lowest possible costs, you need the best possible combination of machinery, machining parameters and tooling solutions. Therefore, we analyse all aspects of the production process involving cutting tools and systematically optimise them. Subsequently, our tool developers define the optimum tooling solution customised to fit your requirements. often, we are able to implement a solution which reduces the number of tools necessary for a certain operation or simplifies the process, thus considerably reducing tooling costs and machining time. all tools are developed and manufactured utilising the latest technology. The optimum tooling solution often includes the unique geometries developed by Kyocera Unimerco which helps to ensure extreme accuracy and tight tolerances. This means that tools can be run at extremely high cutting speeds in balanced conditions utilising the full capability of machine tools and maximising metal removal rates. RE•NEW® – regrinding and repair of all PCD tool brands reliable and profitable production demands professional tool maintenance. RE•NEW® is KYOCERA UNIMERCO’s full-service repair and regrind service of own tools and all other tool brands. The RE•NEW® concept ensures that high productivity, function, and tool life are maintained throughout the life span of the tool – with a performance guarantee. This means that you can confidently run any RE•NEW® tool in production at full speed without compromising, as you would for competitors’ re-ground tools. We call it RE•NEW® because the tool will perform as well re-ground as it will when it is new – if not better! UM SOP™ (Systematic Optimisation of Production) Um SoP™ is a method and optimisation tool which is applied in order to reduce your production unit costs. our sales engineers evaluate customer processes and make constructive suggestions, showing how a new process is implemented and predicting the cost savings. over time, the optimisation data is collected and presented to senior managers to show the projects that have been optimised and the financial benefits to the company. The system maximises the efficiency of both our time – and yours. Um SoP™ is consultancy and is there to increase your productivity and ultimately increase your profits.2012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=3http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=3OPTIMISED PRODUCTION Test facility To stay ahead of the field, we have has set up a 5-axis machining centre for performance testing of new tools using both traditional lubrication and minimum quantity lubrication (mQL). For instance, the tools are tested for function, runout accuracy, tool life, and Kyocera Unimerco also establishes the optimum machining parameters for given applications. Safety stock and tool management if so desired by the customer, Kyocera Unimerco offers to establish a safety stock for urgent deliveries. in return, the customer undertakes to buy the tools in question within a fixed period of time. in additon to this we run fully automated tool management with crib systems to larger customers with a full reporting system to help managers with financial production control. Research and development We believe that the way forward is investment. As well as extensive investment in plant and machinery, heavy investment is made each year in developing new tool solutions for new materials and applications. Kyocera Unimerco is currently undertaking research projects with major universities around the world into cutting solutions for the latest materials, some of which are seen today as ‘impossible to cut’. Working with us will give you access to the latest technology and help you increase your productivity through performance cutting solutions. Implementation in our opinion, tool delivery is just part of the total solution. The most efficient production situation is achieved only if the tool is used correctly. Thus, our optimisation experts will assist during this phase with advice concerning cutting parameters, cooling, production reliability and will optimise production for you. Why a partnership? Long-term improvement of competitiveness demands a serious and permanent cooperation in which both parties work together to improve productivity. That is why Kyocera Unimerco is the preferred tooling partner for the aerospace industry. Fast delivery The standard delivery time on solid carbide is 2-3 weeks and 4-6 weeks for PcD. a complete programme of standard mills, drills, countersinks, reamers and spindle nose tooling is available ex. stock (see page 19). The manufacturing capacity in Denmark (2 sites), the UK and USa, enables us to carry out fast deliveries of tools. This means that you carry less inventory and ultimately have less cash tied up in stock. www.kyocera-unimerco.com 32012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=4http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=4FOCUS SEGMENTS CUTTING TOOLS FOR ALL MATERIALS We specialise in the design and manufacture of cutting tools to machine all aircraft materials from the softest aluminium to the hardest nickel alloys and most abrasive CFC’s. By breaking a typical aircraft down into focus segments, Kyocera Unimerco has developed the correct tool materials, geometries and coatings to optimise production solutions and improve component accuracy in all materials and applications. This means that all Kyocera Unimerco customers can benefit from a standard or special tooling solution that is ’fit for purpose’, competitively priced and delivered within a short period of time. The result is that our customers can produce higher quality components faster, which results in lower costs and a competitive edge in a difficult market. MATERIALS › Light alloys › AlSi alloys › MMC’s (metal matrix composites) › Fibre composites › Fibre composite/metal stacks › Titanium alloys › Nickel alloys › Stainless steels SEGMENT OVERVIEW AIRFRAME AVIONICS › › › › › one-shot drilling of cFc/metal stacks orbital drilling tools one-way assembly drill/countersink tools PcD and cVD diamond solutions for cFc milling and drilling c7 nanocomposite coating technology for milling and drilling. › Diamond cutting tools for high silicon alloys › Long-reach special tooling › anti-chatter milling tools. › concentricly adjusted tooling to within 1 micron t.i.f. AEROSTRUCTURE CONTROL SYSTEMS › High performance machining of titanium and steel structures › High speed machining of Ti and aluminium alloys › cutting tool solutions from carbide and PcD for aerostructure materials › c7 nanocomposite for max. performance in titanium. › High accuracy solutions for hole finishing › Port boring tools for one-shot hole manufacturing › Standard and high performance drills, taps, thread mills and reamers. 4 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=5http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=5AERO ENGINE › › › › › › Blade and blisk milling cutting tools root-form tools (brazed and solid carbide) multi dia-drilling of exotic materials High surface generation rate 5-axis milling solutions Specialist in machining nickel alloys c7 for titanium, nickel alloys and stainless steels. www.kyocera-unimerco.com 52012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=6http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=6AEROSTRUCTURE INTRODUTION The aerostructure segment covers the manufacture of machined components from light alloy ribs and spars, titanium struts and pylons through to steel landing gear components. Kyocera Unimerco specialises in standard and special tool solutions for milling and drilling structure components. From conventional machining to high speed machining of soft alloys, right through to high performance milling of hard metals, we have a solution that will reduce cycle times, improve quality and increase profitability. our technical department specialises in bespoke solutions for all sizes of component in any material. The aerostructure market has moved towards monolithic structures that have thin walls and deep pockets. This is where maintaining surface finish and accuracy can cause problems with conventional tooling. call us for the ultimate engineered solution in these applications. TOOL EXAMPLES DRILL PCD ROUTER Standard and special performance drills one-shot drill negates the need for a spotdrill, thus saving time. Through coolant to evacuate swarf from holes and aid cooling means longer tool life. multi-diameter h7 hole tolerance drills available upon request. PCD tooling for high speed milling of light alloys High-speed milling reduces cycle times and allows for efficient machining of thin walls without chatter. excellent surface finish can be achieved which means higher quality components. Up to 50 × tool life over solid carbide improves tool economics and reduces the number of tool changes. STUB UM WAVE TOOL Solid carbide tools for milling nickel alloys and titanium Stub design tools offer high rigidity and can cope with high tooth loads so high feed rates can be used. Wave flute design stabilises chatter, allowing deeper cuts and thus increasing metal removal rates. cutting geometry for roughing and finishing means fewer tools and tool changes. c7 coating can significantly extend tool life and allow higher surface speeds. LONG UM WAVE TOOL Solid carbide performance tools for hard metals optimised designs for machining hard metals means that higher metal removal rates can be achieved – thus increasing productivity. Special flute design allows for very deep roughing cuts, reducing cycle times. cutting geometry for rough and finish machining means less tools are required – ultimately reducing costs. 6 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=7http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=7COMPONENT EXAMPLES CARBIDE ROUTER Solid carbide performance tools for light alloys Tough carbide grade allows for very high feed rates, thus increasing productivity. Special geometry enhances surface finishes and improves component quality. CNC ground with ’customer-specified’ flute length, reach or corner radius means the right tool for the job and optimises productivity. PCD HSK INTEGRAL ROUTER Integral performance PCD tooling for light alloys integral design with increased stiffness allows deeper cuts without chatter. Tough diamond suitable for aero alloys means that the tools last significantly longer than carbide-tipped equivalents. Through coolant for effective chip evacuation results in no re-cutting of swarf (suitable for mQL). PcD gives a mirror finish on pocket bases. MULTIFLUTE FINISHING TOOL Solid carbide performance tools for high speed cutting of exotic materials Different geometry design for different metals optimises cutting performance. Suitable for high speed machining which reduces cycle times. excellent surface finishes improve component quality, thus reducing post machining operations. PCD TEE SLOT CUTTER Special PCD tooling for difficult applications extremely high rigidity means that higher cutting parameters are achieved. PcD is 5 times harder than carbide which means less abrasive wear to cutting edges and it has a 6 × lower coefficient of friction to eliminate built-up edge on the tool. We design the correct tool solution to fit the exact customers specification so that the cutting process is optimised. www.kyocera-unimerco.com 72012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=8http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=8AERO ENGINE INTRODUTION The aero-engine segment covers the manufacture of machined engine components from titanium blades, blisks and casings through to nickel alloy ‘hot end’ components. Kyocra Unimerco specialises in standard and special tool solutions for milling and drilling engine components. From blade root form milling to high speed machining of blade aerofoils and snubbers, right through to high-performance milling of hard metals such as disks and shafts, we have a solution that will reduce cycle times, improve quality and increase profitability. our technical department specialises in bespoke solutions for all sizes of component in any material. The market has moved towards blisks with longer, thinner blades and is investigating materials such as gamma titanium aluminide. This is where maintaining surface finish and accuracy can cause problems with conventional tooling. call us for the ultimate engineered solution in these applications. TOOL EXAMPLES STUB DRILL COATED MULTI DIAMETER DRILL Special drills for optimum performance on casings and rings Bespoke designs give the exact tool for the job so productivity and accuracy is maximised. choice of point types and flute configurations to give the best quality hole and consistency which reduces non-conformance. Through coolant chills the tool/chip interface and extends tool life. Step drills to increase accuracy and minimise tool change mult-diameter drills to reduce 3 or 4 tools down to 1! one shot h7 drill/chamfer tools reduce cycle time significantly thus freeing up machine capacity. Different coatings are available for drilling different metals to increase tool life and reduce tool costs. Full RE•NEW® (regrind/recoat) with ‘as new’ guarantee means that tools perform consistently, this reduces cycle costs whilst giving confidence in production. BACK CHAMFER/FORM TOOL Back chamfer tools Single flute tools to chamfer the back of holes, made from brazed carbide, solid carbide and PcD. The result is the reduction in process time from reducing the number of operations. Simply feed through the hole, move to centre, start the spindle and feed to produce the feature – effortless and in a controlled process. ROOT FORM CUTTER Brazed and solid carbide root form cutters Brazed carbide and solid carbide root form cutters cnc ground to achieve high accuracy and repeatability. Shank or bore tool designs to suit customer specific applications mean that highest mmr is achieved. controlled grinding process ensures that we can guarantee the root form and the customer benefits from increased confidence and process reliability. 8 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=9http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=9COMPONENT EXAMPLES BALLNOSE LOLLIPOP AND BARREL CARBIDE CUTTERS Ballnose lollipop cutters and barrel mills Lollipop cutters reach difficult areas allowing some 5-axis work to be achievable on a 3 axis machine. any shape of tool can be manufactured with geometry to suit specific metals, which enables high efficiency. increasing the radius to a barrel shape increases the step over dimension when milling 3D surfaces, and significantly reduces cycle times. TORUS CUTTER CARBIDE Torus milling tool Our special design allows high MRR’s and feed rates giving high productivity. Controlled RE•NEW® (re-grinding and re-coating) with guaranteed performance means that this tool works the same whether new or RE•NEW®, giving a stable manufacturing process. Surface coating facilities at all Kyocera Unimerco manufacturing sites means that all tool manufacturing processes are controlled in-house which gives the customer confidence in quality and delivery. TAPER BALLNOSE CUTTER CARBIDE Taper ballnose cutter Bespoke stub flute design tools offer high rigidity and can cope with higher tooth loads so high feed rates can be used. Special flute designs stabilise chatter allowing faster feeds and thus increasing surface generation rates. Suitable for all blade and blisk applications. STUB UM WAVE TOOL Solid carbide tools for milling nickel alloys and titanium Stub design tools offer high rigidity and can cope with high tooth loads so high feed rates can be used. Wave flute design stabilises chatter allowing deeper cuts and thus increasing metal removal rates. cutting geometry for roughing and finishing means fewer tools and tool changes – excellent for scallop milling applications. c7 coating can significantly extend tool life and allow higher surface speeds. www.kyocera-unimerco.com 92012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=10http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=10AVIONIES AND MISSILES INTRODUTION The avionics and missiles segment covers the manufacture of machined components from light alloy castings and titanium brackets, through to metal matrix composites and 60% silicon aluminium alloys. Kyocra Unimerco specialises in standard and special tool solutions for milling and drilling engine components. From blade root form milling to high speed machining of blade aerofoils and snubbers, right through to high-performance milling of hard metals such as disks and shafts, we have a solution that will reduce cycle times, improve quality and increase profitability. our technical department specialises in bespoke solutions for all sizes of component in any material. The market has moved towards blisks with longer, thinner blades and is investigating materials such as gamma titanium aluminide. This is where maintaining surface finish and accuracy can cause problems with conventional tooling. call us for the ultimate engineered solution in these applications. TOOL EXAMPLES PCD TWIN POINT DRILL PCD twin point drill Twin point allows higher feed rates and increases productivity. no single point at centre means lower forces and less damage to components. PcD edges give significant increases in tool life and reduce the manufacturing cost per hole. CARBIDE CUTTER Solid carbide performance tools for light alloys Tough carbide grade allows for very high feed rates thus increasing productivity. Special geometry enhances surface finishes and improves component quality. cnc ground with any flute length, reach or corner radius means that customer specifies the right tool for the job and optimises productivity. BALLNOSE LOLLIPOP CARBIDE CUTTER Ballnose lollipop cutters Lollipop cutters reach difficult areas allowing some 5-axis work to be achievable on a 3-axis machine. any shape of tool can be manufactured with geometry to suit specific metals which enabled high efficiency. Long reach tools allow for machining in extremely difficult areas which reduces extra set ups and post machining operations such as hand benching. PCD ROUTER PCD tooling for high speed milling of light alloys High-speed milling reduces cycle times and allows for efficient machining of thin walls without chatter. excellent surface finishes can be achieved which means better quality components. Up to 50 × tool life over solid carbide improves tool economics and reduces the number of tool changes. 10 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=11http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=11COMPONENT EXAMPLES CARBIDE LONG SERIES DRILLS Extra long and specials drills We specialise in manufacturing accurate long series drills which means good hole quality – consistently. Special multi-diameter drills to cut any material are designed and manufactured in-house taking the problem away from the customer and releasing time. HSS, carbide and PcD with a choice of coatings including cVD diamond means that we can offer a solution to the most problematic holes. PCD INTEGRAL FACEMILL PCD facemills with fixed or changeable inserts integral design or bore/spigot and the correct geometry allows for deeper cuts at high speeds. Tough diamond suitable for aero alloys means that the tools last longer and produces ’mirror finishes’. Through coolant for effective chip evacuation means no re-cutting of swarf (suitable for mQL). available as shown with brazed inserts or with replaceable cartridges to suit all applications. PCD FORM ROUTER CD special tooling for high speed milling High-speed milling reduces cycle times. excellent surface finishes means better quality components. Up to 50 × tool life over solid carbide means that very long scanning cycles can be used with only one tool and ’mirror finishes’ are achieved on components. UM WAVE Solid carbide UM wave tools for hard metals optimised designs for machining hard metals means that metal removal rates can be increased. Special flute design allows for very deep roughing cuts reducing cycle times. cutting geometry for roughing and finishing means less tools are required – ultimately reducing costs. available with c7 nanocomposite or cVD diamond coating to extend tool life. ‹ ’Barrel-end geometry’ for surface machining www.kyocera-unimerco.com 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=12http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=12CONTROL SYSTEMS INTRODUCTION The control systems segment covers the manufacture of machined components from light alloy and titanium hydraulic control boxes through to stainless steel barrels with close tolerance bores. Kyocera Unimerco specialises in standard and special tool solutions for milling and drilling these components. From conventional machining to high-speed machining of soft alloys and titanium, right through to high accuracy, multi-diameter drill/ream/ port boring applications, we have a solution that will reduce cycle times, improve quality and increase profitability. UNIMERCO’s technical department specialises in bespoke solutions for all sizes of component in any material. The market has moved towards more complex components with very deep holes and complex port features that are designed with tighter tolerances than ever before. This is where maintaining surface finish and accuracy can cause problems with conventional techniques. call us for the ultimate engineered solution in these applications. TOOL EXAMPLES BACK CHAMFER/FORM TOOL Back chamfer tools Single-flute tools to chamfer the back of holes, made from brazed carbide, solid carbide and PcD. The result is the reduction in process time from reducing the number of operations. Simply feed through the hole, move to centre, start the spindle and feed to produce the feature – effortless and in a controlled process. CORE/CHAMFER/COUNTERBORE Multi diameter core/step drills and reamers Kyocera Unimerco specialises in manufacturing accurate multi-diameter drills and reamers which means good hole quality – consistently. Special tools to cut any material are designed and manufactured in-house taking the responsibility away from the customer and releasing engineering time. HSS, carbide and PcD with a choice of coatings including cVD diamond means that we can offer a solution to the most problematic holes. LONG UM WAVE TOOL Solid carbide performance tools for hard metals optimised designs for machining hard metals means that higher metal removal rates can be achieved – thus increasing productivity. Special flute design allows for very deep roughing cuts, reducing cycle times. cutting geometry for rough and finish machining means less tools are required – ultimately reducing costs. CARBIDE ROUTER Solid carbide performance tools for light alloys Tough carbide grade allows for very high feed rates, thus increasing productivity. Special geometry enhances surface finishes and improves component quality. CNC ground with ’customer-specified’ flute length, reach or corner radius means the right tool for the job and optimises productivity. 12 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=13http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=13Some images courtesy of Quadrant Picture Library COMPONENT EXAMPLES STEPDRILL/FORM SPOTFACE TOOL CARBIDE Drill/c’bore/spotface form tool This tool reduces 4 individual tools down to 1 tool. The result is significantly lower cycle time and improved productivity. only one toolholder is required, saving money on holders and freeing capacity in the tool carousel. (See our range of toolholders on page 19). TEE SLOT UNDERCUT TOOL Tee slot cutter available from HSS, carbide and PcD, we offer solutions for all materials. Long- reach solutions are available making the most difficult applications less problematic. Straight or staggered flute designs to suit individual applications allow maximum mrr and increase productivity. STEPDRILL/CHAMFER TOOL CARBIDE Carbide and PCD drill/chamfer tools one shot h7 drill/chamfer tools reduce cycle time significantly thus freeing up machine capacity. Different coatings are available for drilling different metals to increase tool life and reduce tool costs. Full RE•NEW® (regrind/recoat) with ‘as new’ guarantee means that tools perform consistently, this reduces cycle costs and maintains confidence in production. UNDERCUT O’RING GROOVE/FORM TOOL Undercut/grooving tools extremely complex tools with many different features significantly reduce the number of tools required in a process. Special geometry enhances surface finishes and improves component quality in critical areas. accurately cnc-ground to any profile shape means that the correct size and form is produced on the component, giving consistency between batches and eliminating the risks involved with setting multiple tools. www.kyocera-unimerco.com 132012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=14http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=14AIRFRAME INTRODUTION The airframe segment covers the drilling, surface machining and trimming of composite components and the assembly machining of composites and stack materials such as cFc/aL and cFc/titanium, one way assembly tools and orbital drilling tools. Kyocera Unimerco specialises in standard and special tool solutions for milling and drilling airframe components. From trimming CFC’s to one shot drilling of carbon fibre stacks with Cpk’s of >3.5, we have a solution that will reduce cycle times, improve quality and increase profitability. our technical department specialises in bespoke solutions for all sizes of component in any material. The market has moved towards composite structures that have thicker sections and include hard metals in places. This is where maintaining tool life and hole accuracy can cause problems with conventional methods. call us for the ultimate engineered solution in these applications. TOOL EXAMPLES PCD FORM ROUTER PCD special tooling for high-speed milling High-speed milling reduces cycle times. excellent surface finishes means better quality components. Up to 50 × tool life over solid carbide means very long scanning cycles can be used with only one tool and ’mirror finishes’ are achieved on components. UP/DOWN/CUTTER Carbide and PCD up/down cutter High-speed milling reduces cycle times and allows for efficient machining of thin components without chatter. excellent surface finishes can be achieved which means better quality components The up/down geometry holds thin components steady, reducing vibraton – this increases tool life and component quality. REAMERS/C’SINK TOOL BRAZED CARBIDE ON STEEL BODY Brazed carbide drill/c’sink tools Specifically designed for large hole applications where the drill dia is >15mm. one shot drilling, core drilling or reaming means less tools are used and cycle times are reduced. Brazed carbide cSK design is highly cost effective in hole diameters >15mm compared to solid carbide tools. PCD HSK INTEGRAL ROUTER Integral performance PCD tooling for light alloys integral design with increased stiffness allows deeper cuts without chatter. Tough diamond suitable for composite skin milling allows skin profiles to be machined with minimum tool wear. This reduces the cost per cut and maintains component accuracy. 14 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=15http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=15” COMPONENT ASSEMBLY” Some images courtesy of BAE systems C7 NANO-COMPOSITE AND CVD DIAMOND COATED DRILLS Coated drills High-performance drilling of cFc materials reduces cycle times in cnc or power feed applications. increased life reduces the tools costs per hole. as an alternative to PcD, c7 or cVD diamond, coating can be applied to tools with any geometry thus allowing optimised tool designs. c7 is regrindable and may offer lower life cycle costs than cVD diamond tools. CVD DIAMOND, PCD AND CARBIDE ORBITAL DRILLING TOOL Orbital drilling tools orbital drilling is new technology for airframe hole production. With each application totally different, KYocera Unimerco has tool solutions to suit your needs. carbide, c7 or diamond coated and PcD tool options are designed to offer process reliability and high accuracy. VEINED PCD DRILL/C’SINK TOOL Veined PCD drill c’sink tools Veined PCD is where diamond is ‘grown’ into helical-geometry tools. a variety of forms of drill c’sink tools are available to increase productivity and hole quality. The exact geometry can be applied directly to diamond, thus giving the best tool for cFc drilling. regrindable up to 3 times – improves economics. h8 one-shot drilling applications reduce the need for multiple tools. VEINED PCD DRILL/ C’BORE PORTABLE DRILL UNITS Veined PCD multi diameter drills Veined PcD offers 30 × life over uncoated carbide in abrasive applications. a sharper edge than cVD diamond and renewable means that cost per hole can be reduced significantly in cnc applications. Veined PcD allows carbide geometry to be applied to diamond, giving a clean effectively cutting action and achieving high accuracy. www.kyocera-unimerco.com 152012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=16http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=16CASE STORY POCKET MILLING AIRFRAME COMPONENT The airframe segment covers the drilling, surface machining and trimming of composite components and the assembly machining of composites and stack materials such as cFc/aL and cFc/titanium, one way assembly tools and orbital drilling tools. Kyocera Unimerco specialises in standard and special tool solutions for milling and drilling airframe components. From trimming CFC’s to one shot drilling of carbon fibre stacks with Cpk’s of >3.5, We have a solution that will reduce cycle times, improve quality and increase profitability. our technical department specialises in bespoke solutions for all sizes of component in any material. The market has moved towards composite structures that have thicker sections and include hard metals in places. This is where maintaining tool life and hole accuracy can cause problems with conventional methods. call us for the ultimate engineered solution in these applications. OLD METHOD 3 cuts: rough: Semi finish: Finish: 9,000 rpm and 500mm/min – 5mm deep 9,000 rpm and 500mm/min – 1mm radial 9,000 rpm and 500mm/min – 0.1mm radial › NEW METHOD 1 cut: rough and finish: 18,000 rpm and 3,600mm/min – 5mm deep Cycle time = 9.2 min Cycle time = 1.1 min Standard solid carbide router UNIMERCO PCD router CYCLE TIME REDUCED BY 88% 16 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=17http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=17CASE STORY POCKET AND SLOT MILLING TITANIUM FORGING High-performance roughing of titanium using Um wave. This optimisation was conducted to increase productivity whilst rough milling titanium. The current benchmark was a 0.5xD deep slotting cut using a HSSco Ticn coated ripper. The Um wave cutter with c7 coating is designed for high performance, deep slot milling of exotic alloys. Using this tool the depth of cut was doubled to 1×D while at the same time the cutting speed was doubled. Um wave can also be used for finish machining which negates the need for separate roughing and finishing tools. OLD METHOD 10mm deep × 20mm wide cut 30m/min at 0.08mm feed/tooth › NEW METHOD 20mm deep × 20mm wide cut 60m/min at 0.08 feed/tooth Coated HSSCo ripper C7 coated UM wave TWICE DEPTH AND TWICE SPEED = PRODUCTIVITY INCREASE OF 400% www.kyocera-unimerco.com 172012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=18http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=18CASE STORY ASSEMBLY DRILLING OF AIRCRAFT SKIN One shot drilling of CFC/aluminium stack The objective in this application was to reduce costs. The current process utilised a competitors PcD drill and PcD reamer. The total cost per hole was significant but only PcD was capable of cutting this type of material. our solution utilised veined PCD which allows ‘carbide-style’ geometry to be applied to diamond (PcD). The result was a significant reduction in hole costs and a very high process capability. Veined PcD is used across the aerospace and formula 1 industries and is particularly effective in highly abrasive applications. OLD METHOD 2 shot solution – drill and ream: Cost/hole = £ 1.67 › NEW METHOD 1 shot hole with >3.5 Cpk: Cost/hole = £ 0.36 Brazed PCD drill and reamer Veined PCD One shot drill HOLE COST REDUCED BY 78% 18 Kyocera Unimerco Tooling a/S Tel. +45 97 14 14 112012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=19http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=19STANDARD PROGRAMME INTRODUCTION TO THE UM CATALOGUE Catalogue structure Kyocera Unimercos core business is the manufacture and RE•NEW® of special tools to optimise customers production. In addition to this, we offer a complete tooling programme. This is available in the Um catalogue. The catalogue is based on the Um concePT™ and includes a number of products and services aiming at reducing unit costs and improving competitiveness. The catalogue is user-friendly and symbols have been used extensively to explain tool properties. all necessary information on recommended cutting data and material classes has also been included on the pages, where relevant. We have aimed at making the catalogue as easy to use as possible but choice of tool and cutting data will always depend on the specific situation. Please contact one of our technical sales engineers who will help you choose the right tools and optimum cutting parameters. CHAPTERS OVERVIEW Milling › HSS and HSS Pm end mills › Standard and high performance carbide end mills › customised milling cutters Surface coating › Tribology centre › coating of cutting tools › coating of non-cutting tools Drilling › High performance carbide twist drills › High performance carbide straight flute drills › High performance carbide three flute drills Toolholding systems › complete toolholding programme › collet chucks/hydraulic chucks/ shrink fits › Systems from nikken and Schunk Thread cutting tools › HSS and HSS Pm taps › HSS fluteless taps › Thread milling cutters › Dies Tool maintenance › RE•NEW® carbide tools › RE•NEW® and re-tip PCD tools › RE•NEW® veined PCD tools Countersinks and reamers › HSS countersinks › carbide countersinks › HSS reamers › carbide reamers Tool management › Tool lockers › autocrib dispensing stations › UNI•SERVICE Diamond tools › PcD milling cutters › PcD drills › PcD special tools Training and education › Standard courses › Special courses › Production analysis › Theme days www.kyocera-unimerco.com 192012-04-03T15:56:11+02:00http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=20http://nozebra.ipapercms.dk/Unimerco/064/UK/PM/0641009PMUKUKfocussegments/?Page=20KYOCERA UNIMERCO Tooling A/S KYOCERA UNIMERCO manufactures, distributes and services tools for machining, as well as measuring equipment for the manufacturing industry. The tooling concept comprises standard and customised tools, RE•NEW® tool maintenance, coating and optimisation guidance. The Danish company was established in 1964 and has product development, production, sales and service in the corporate headquarters, located in Sunds. The company is part of the KYOCERA UNIMERCO group, founded in Denmark in 1964 and originally named UNIMERCO. In 2011, all activities were acquired by Japan-based KYOCERA. This has created an even stronger company with a larger range of products, a wide network of companies and distributors all over the world, and an ambitious growth plan. Drejervej 2 DK-7451 Sunds / Denmark Tel. +45 97 14 14 11 Fax +45 97 14 14 86 umdk@unimerco.com www.kyocera-unimerco.com © 09.11 - 064_1009_PM_DK-UK2012-04-03T15:56:11+02:00