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ATI Stellram will unveil its strategy for thin-wall machining of titanium components at the AeroEngineering Show in Manchester from 10-11 November.

The solution provider for difficult-to-machine materials has developed the 8:1 rule, following a programme of testing undertaken by its research team in the US in conjunction with a top aircraft manufacturer.

ATI Stellram’s trials have shown that optimum cutting conditions can be achieved through the combination of a strength ratio of height to width of 8:1 and the application of a variable cutting edge.

‘A wall that is 100mm high needs a minimum width of 12.5mm to support it while machining takes place as any smaller width weakens the wall’s strength and creates unstable cutting conditions,’ said John Palmer, ATI Stellram’s global aerospace manager.

‘The rule, in addition to adhering to the machining steps of roughing, qualifying and finishing, is easy to prove on a profiling application using a standard four-flute end milling cutter to create a thin wall by reducing the width on successive small radial passes.

Providing the cutter is sharp and the speed and feed is correct, the wall will become unstable once the 8:1 ratio is achieved, whatever the axial depth of cut.

He added: ‘For example, a 25mm diameter end milling cutter, machining a 24mm-high wall in successive 0.5mm radial depths of cut, will successfully reduce the wall to 3mm before problems such as deflection and harmonics arise.’ ATI Stellram will also show a variety of cutting tool programmes designed for use on difficult to machine materials.

These include the solid-carbide RSM programme, which has been specifically launched for the machining of titanium air frames.

Stellram to unveil thin-wall titanium strategy

ATI Stellram will unveil its strategy for thin-wall machining of titanium components at the AeroEngineering Show in Manchester from 10-11 November.

The solution provider for difficult-to-machine materials has developed the 8:1 rule, following a programme of testing undertaken by its research team in the US in conjunction with a top aircraft manufacturer.

ATI Stellram’s trials have shown that optimum cutting conditions can be achieved through the combination of a strength ratio of height to width of 8:1 and the application of a variable cutting edge.

‘A wall that is 100mm high needs a minimum width of 12.5mm to support it while machining takes place as any smaller width weakens the wall’s strength and creates unstable cutting conditions,’ said John Palmer, ATI Stellram’s global aerospace manager.

‘The rule, in addition to adhering to the machining steps of roughing, qualifying and finishing, is easy to prove on a profiling application using a standard four-flute end milling cutter to create a thin wall by reducing the width on successive small radial passes.

Providing the cutter is sharp and the speed and feed is correct, the wall will become unstable once the 8:1 ratio is achieved, whatever the axial depth of cut.

He added: ‘For example, a 25mm diameter end milling cutter, machining a 24mm-high wall in successive 0.5mm radial depths of cut, will successfully reduce the wall to 3mm before problems such as deflection and harmonics arise.’ ATI Stellram will also show a variety of cutting tool programmes designed for use on difficult to machine materials.

These include the solid-carbide RSM programme, which has been specifically launched for the machining of titanium air frames.

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