Jet engine turbine blades play an essential role in the turbine section of an aircraft engine are exposed to the harshest environment in terms of pressure and temperature, while rotating at an extremely high speed, necessitating the use of heat-resistant superalloys (HRSAs), such as Inconel and Wasaploy. These materials offer high creep and temperature fatigue strength, and high temperature corrosion resistance; however, these pose significant machining challenges due to their toughness and thermal properties. To address these challenges, MEGATech enthusiastically presents Tungaloy’s advanced cutting tools, providing innovative solutions tailored not only effective for only HRSAs, but also specialized materials like aluminum-lithium alloys and titanium aluminide (TiAl).
The general objectives of introducing these cutting tools are as follows: to improve machining efficiency and chatter of thin-walled sections, to reduce cutting forces when high-feed milling the blade surface in the axial direction for improved machining efficiency, to obtain high-performing cutting tools that maximize 5-axis machines, and to maintain high part precision.
TungMeister-Barrel head, a high surface finish milling of blade surfaces with improved cycle time on 5-axis machines, offers longer tool life, shorter cycle time, and smoother surfaces compared to the traditional ball nose mills. The cutter’s peripheral cutting edges feature a large curvature radius that facilitates a much greater engagement area between cutter and workpiece than typical ball nose counterparts. Greater engagement area, in turn, enables larger stepovers, which improve metal removal rates and surface finish with less tool wear. Barrel milling heads are available for selection in three profiles, depending on the type of finish required to achieve: VBO-short for semi-finishing of general parts, VBO-long for pre-finishing and finishing of die mold parts, and VBN for pre-finishing and finishing of turbine blade surfaces and roots, impellers, blisks, and other aerospace parts.
TungMeister-Barrel
Maximum Stock Removal with DoFeed
Furthermore, DoFeed, an ultimate high feed milling cutter series with close-pitched insert alignment, is designed for efficient removal of large stock and reduced cycle time for roughing operations. Its double-sided insert geometry brings benefits in tool economy and productivity. Additionally, the negative inserts generate low cutting force, eliminating vibration. A wide range of selection of tool lineup is available for selection for expanded application coverage.
DoFeed
Unmatched Machining Performance with SolidMeister Lastly, the SolidMeister offers a comprehensive selection of solid carbide endmills to enhance machining efficiency and stability in a broad spectrum of applications. These endmills include the FinishMeister, a combination of roughing edges and finishing edges and can perform roughing and finishing operations at the same time, the VariableMeister, which as a variable pitch configuration and features its excellent chatter dampening ability, and lastly, the FeedMeister, which is for high feed milling and it is the line up of the latest solid ceramic tools.
SolidMeister
In conclusion, with Tungaloy’s advanced cutting solutions, superior performance, efficiency, and precision is ensured in machining HRSAs and specialized materials. From high-feed milling to exceptional surface finishing, these innovations enhance productivity, extend tool life, and optimize machining processes without imposing stresses on cutting tool edges, meeting the demanding requirements of modern aerospace manufacturing.
