EM Jan 2015

A e r o s pa c e M a n u fa c t u r i n g | F O C U S

Fig 1: Aerospace is a key market for composites

Fig 2: Drilling and reaming account for 70 per cent of composite machining operations

No ISO standards The vast breadth of composites available in the marketplace means that there is no ISO standard for these materials as there is for metals. Subsequently, every individual machining process and cutting tool solution must be tailored to specific customer requirements to achieve the desired outcome. The most common composite material for engineering applications is the group known as carbon fibre reinforced plastic (CFRP). The matrix of most CFRPs is generally a polymer resin such as epoxy, although polyester, vinyl ester and nylon are also used.

The resin binds the reinforcements together. Besides carbon, the ‘fibre’ element of the mix can include aramid, Kevlar or glass, for instance. Frequently, these composite reinforcement materials have been pre-impregnated with activated resin. Here, the epoxy resin, which has previously been mixed with hardener, is impregnated into the dry reinforcement fabric to create what is known as a ‘pre-preg’. Metals such as titanium and aluminium are often stacked in layers with the CFRP to introduce additional design properties. Double stacking (CFRP-Al-CFRP-Ti) is also on the increase, with stainless steel even included for some applications. In turn, these combinations present additional machining challenges: burr formation is a common criterion with titanium and chip control with aluminium, for example.

In every case, the material must be identified in relation to surface, structure, fibres, resin and thickness. With stacks, the combination of metal type and thickness are relevant factors.

a successful, cost efficient process. The volume of holes to be produced, for example, impacts tool selection in that a large quantity in one type of composite material must be made efficient using an optimised, typically more expensive tool. A smaller quantity of holes, combined with the ability to accommodate the variation in composites, components and set-ups, indicates a different tool choice. The amount of operations required to finish a hole in a composite component is a further productivity factor increasing in prominence, as is the eradication of operations such as deburring. Recently, specific tool development has contributed to applications where four holemaking operations have been reduced to one using a more suitable, modern tool. This was achieved by eliminating pre-drilling, reaming and de-burring. One-shot operations can obviously impart huge influence on the economics of manufacturing when high volumes of holes need to be generated.

Tool changing is another influential productivity factor and one that is easily improved using the right technology. Quickchange toolholders, for instance, can reduce this task to just a few minutes at most. Modern toolholding concepts feature high-tech couplings between the spindle interface unit and cutting unit that is easily and quickly changed with high accuracy. Exchangeable head systems are also available, where the head can be changed in a few seconds. Not having to remove the tool shank and or perform any further pre-setting of the cutting edge results in minimal machine stoppages for tool changes.

Commercial considerations

Tool materials

In the aerospace industry, making holes is a dominant driver of efficiency and cost issues, and there are many ingredients to

Cemented carbide offers ways to strengthen the tool through the cutting geometry as well as through the shank of the drill,

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h i g h l i g h t s | c o m pa n y i n d e x | Im p r i n t

Highlights - February 2015 »»Die & Mould Die and mould makers in India can today compete globally and have over the years recorded transformational and high all round market growth. The main issue in Indian tool rooms is shortage of capacities which is met through imports

by OEMS. The large scale growth in manufacturing capacity will be needed to meet the demands of large number of OEMs desiring to make India their global manufacturing hubs. The next issue takes a look at the trends that would lead to rapid manufacturing growth of toolings. .

»»Manufacturing IT Manufacturing IT plays an important role in the manufacturing technology development. Get to know about the new technologies in Manufacturing IT in the next issue of EM. »»Grinding Machines Ultra-precision grinding technology for electronic & optical parts has been improved mainly because of advancement in grinding technology using free abrasive grains. The next issue highlights the recent developments in grinding machines.

»»Engineering Materials Material technology has advanced by leaps with development of many new materials with extraordinary properties suited for industrial use. Read about the latest in thermoplastic and thermoset polymers, metals, ceramics, semiconductors, fibres, and other engineering materials in our forthcoming issue.

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Godrej & Boyce Mfg Co Ltd . . . . . . . . . . . . . 34 Haas Automation . . . . . . . . . . . . . . . 1,12, 102 Haimer India . . . . . . . . . . . . . . . . . 7, 160, 163 HEIDENHAIN . . . . . . . . . . . . . . . . . . . . . . . . 52 Hannover Milano Fairs India . . . . . . . . . . . . . . 31 Hong Ji Precision Machinery . . . . . . . . 137, 146 Hyundai WIA India . . . . . . . . . . . . . . . . . . . . 49 IFM electronic India . . . . . . . . . . . . . . . . . . 125 igus . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 116 IMTMA . . . . . . . . . . . . . . 14, 34, 75,149, 154 Ingersoll Rand . . . . . . . . . . . . . . . . . . . . . . . 20 Italian Technology Center . . . . . . . . . . . . . . . 83 Jainnher Machine Co . . . . . . . . . . . . . 141, 148 Jin Year Precision . . . . . . . . . . . . . . . . . . . 166 Jaya Hind Industries . . . . . . . . . . . . . . . . . . . 14 Jyoti CNC Automation . . . . . . . . . . . . . . 5,163 JMTBA . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Kaifeng Machinery Co . . . . . . . . . . . . . 44, 146 Kamikaze . . . . . . . . . . . . . . . . . . . . . . . . . 159 Kim Union Industrial Co . . . . . . . . . . . . 134, 146 Kinol Lubes Pvt Ltd . . . . . . . . . . . . . . . . . . . 41 Kluber Lubrication India . . . . . . . . . . . . . . . 103 Komet Precision Tools India . . . . . Front Gate Fold Kollmorgen . . . . . . . . . . . . . . . . . . . . . . . . 128

ElectroMech . . . . . . . . . . . . . . . . . . . . . . . . 69 EMAG India . . . . . . . . . . . . . . . . . . . . 85, 164 Emuge India . . . . . . . . . . . . . . . . . . . . . . . . 63 Ervin Junker Maschinenfabrik . . . . . . . . . . . . 77 Everising Machine Co . . . . . . . . . . . . 146, 147 ExxonMobil Fuels & Lubricants . . . . . . . . . . . 26 Fatty Tuna India . . . . . . . . . . . . . . . . . . . . . . 88 Festo Controls . . . . . . . . . . . . . . . . . . . 91,161 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . . 38 Flir Systems . . . . . . . . . . . . . . . . . . . . 97, 166 Femco . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 GF Machining Solutions . . . . . . . . . . . . . . . . 21 Grind Master . . . . . . . . . . . . . . . . . . . . . . . . 12 Gifu Enterprises . . . . . . . . . . . . . . . . . . . 4, 144

Korloy India . . . . . . . . . . . . . . . . . . . . . . . . . 23 Klingelnberg India . . . . . . . . . . . . . . . . . 22, 78 Laxmi Machine Works . . . . . . . . . . . . . . . . . 25 LK Machinery Corp ( Taiwan ) . . . . . . . 139, 148 MAG India . . . . . . . . . . . . . . . . . . . . . . . . . 81 Marox Tools Industrial . . . . . . . . . . . . . 144, 147 Marposs India . . . . . . . . . . . . . . . . . . . . . . 162 Micromatic Grinding Technologies . . . . . . . . . 17 Mitsubishi Heavy Industries . . . . . . . . . . . . . . . 2 MotulTech India . . . . . . . . . . . . . . . . . . . . . . 33 Nicolas Correa, SA . . . . . . . . . . . . . . . . . . . 57 Nippei Toyama India Pvt Ltd, . . . . . . . . . . . . 109 Omron Automation . . . . . . . . . . . . . . . . . . . . . 3 Optical Gaging (S) Pte Ltd . . . . . . . . . . . . . . 127

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Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net

company Index Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Ace Micromatic Group . . . . . . . . . . . . . . . . 131 Ann Way Machine Tools . . . . . . . . . . . . . . . 100 Ansys . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 ARC Advisory Group . . . . . . . . . . . . . . . . . . 38 Autocam Technology Co . . . . . . . . . . . 133, 144 Autogrip Machinery Co . . . . . . . . . . . 136, 148 Aequs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 B&R Industrial Automation . . Cover, 10,11, 120 Benign Enterprises . . . . . . . . . . . . . . . . . 36,37 BCG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 BFW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Blaser Swisslube . . . . . . . . 104, 119, 163, 164 Blum Novotest Measuring & Testing . . . . . . . . 45 Bosch Rexroth India . . . . . . . . . . . . . . . . . . . 79 CAD/CAM Publishing . . . . . . . . . . . . . . . . . . 62 Chiron India Machine Tools . Front Inside Cover, 43, 164 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 155 Comsol Multiphysics . . . . . . . . . . . . . . . . . . 51 Cumberland Group . . . . . . . . . . . . . . . . . . . 38 Da Jie Electricity Machinery Industrial . . . . . . . 50 Dees Hydraulic Industrial Co . . . . . . . . . . . . 117 Dormer Tools . . . . . . . . . . . . . . . . . . . 65, 163 DP TECHNOLOGY INDIA (ESPRIT CAD CAM) . 95, 114 Drass Mechatronics & Machinery . . . . . . . . . . . 8

impRINT

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Premium Transmission . . . . . . . . . . . . . . . . . 38 Quaker Chemicals . . . . . . . . . . . . . . . . . . . . 13 Renishaw . . . . . . . . . . . . . . . . . . 55, 162, 164 Ricoh India . . . . . . . . . . . . . . . . . . . . . . . . . 99 Rollomatic India �������������������������������������������93 Ringier Trade Media . . . . . . . . . . . . . . . . . . 138 Renaissance Services . . . . . . . . . . . . . . . . . . 70 Royal Precision Tools Corporation . . . . . 135, 148 Sahajanand Laser Technology . . . . . . . . 73, 161 Sandeep Engineers ( Witte ) . . . . . . . . . . . . . 59 Sandvik Coromant . . . . . . . . . . . . . . . . 46, 165 Seco Tools . . . . . . . . . . . . . . . . . . 86,87, 165 Shenzhen Henfux Technology Co. . . . . . . . . 167 Shuter Enterprise . . . . . . . . . . . . . . . . 145, 147 Starrag India . . . . . . . . . . . . . . . . . . . . 16, 101 Strausak . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Suhner India . . . . . . . . . . . . . . . . . . . 113, 166 Schaudt . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Stratmann Consulting . . . . . . . . . . . . . . . . . . 38 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 TaeguTec India . . . . . . . . . . . Back Inside Cover Tata Motors . . . . . . . . . . . . . . . . . . . . . . . . 38 Tongai Machine & Tool . . . . . . . . . . . . . . . . 143 Taiwan Association of Machinery Industry . . . . 53 Taiwan Diamond Industrial Co . . . . . . . 157, 166 TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . 124 Tyrolit India Superabrasive Tools . . . . . . . 71, 162 TMBA . . . . . . . . . . . . . . . . . . . . . . . . . . 132, UCAM . . . . . . . . . . . . . . . . . . . . . . . . . 24, 67 United Grinding GmbH . . . . . . . . . . . . . . . . 111 VDMA India . . . . . . . . . . . . . . . . . . . . . . . . 38 Walter Tools . . . . . . . . . . . 16, Back Cover, 165 Wendt India . . . . . . . . . . . . . . . . . . . . . . . 123 Wikus India . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wohlhaupter India . . . . . . . . . . . . . . . . 61, 165 Yamazaki Mazak India . . . . . . . . . . . . . . . . . 15 YG1 Cutting Tools Corporation . . . . . . . . . 18,19

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EM | Jan 2015

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