Brindley Metals works hard to provide first class materials and services. This is something we have done for years, resulting in us amassing a huge amount experience. We are also aware that every customer requires something different. They may need titanium grade 5 (6AL4V) plate/sheet or something else. Whatever the case, we tailor the way we work to meet your needs.
Aircraft industry providers machine titanium more often
Titanium and aluminium alloys have a plethora of similarities. For example, we use the metals to create aircraft structural components. Also, in both cases, the component may need you to mill 90% of the material away before you complete the part. Plenty of individuals probably wish the two metals had more in common.
Aircraft industry providers comfortable working with aluminium are likely finding themselves machining far more titanium. The reason is newer aircraft designs make more use of it.
Many shops already have more titanium machining capacity than they realise. Various techniques are not difficult to use. But, few shops use all the available ones for productively milling this material. There are no requirements for titanium to be difficult to deal with. You just have to consider the whole process. Any one element has the capacity to impact the overall effectiveness.
Stability is essential here. When your tools touch the workpiece, they close a circle. The workpiece, fixturing, tables, ways, column, spindle, toolholder, and tool are all part of it. All of them must be stable. Other considerations are vital here as well. In this article, we will discuss some of them so you can be successful with titanium grade 5 (6AL4V) plate/sheet and other materials.
Low radial engagement
Firstly, you need to keep radial engagement low. Heat dissipation is one of the main obstacles with titanium. The thing to keep in mind is much of the heat from machining goes into the tool. With other metals a larger amount goes into the chips instead. You must plan for this to preserve the tooling.
Full slotting only needs a relatively low surface speed. Although, minimising the radial engagement lowers the time the cutting edge produces heat. It allows more time for cooling prior to entering the material on the next rotation.
For finishing here, you can use a milling procedure. It should include an extremely small arc with a honed, sharp cutting edge as well as minimal feed per tooth and high surface speed. It will produce exceptional results.
Increase flute quality
Many mills possess four or six flutes. For titanium, this may not suffice. An effective amount could be ten or more. Increasing the flute number compensates for the requirement for lower feeds per-tooth. The close flute spacing of a 1-flute utensil is going to be too tight for chip clearance in various projects. Yet, productive titanium milling favours a low radial depth already. The small chip that results from this offers you the freedom to employ a high-flute-count end mill to enhance productivity. Come to us if you need titanium grade 5 (6AL4V) plate/sheet items.
Always arc in
In titanium and other metals, tool life drops in periods of jarring force changes. The worst of such moments usually happens when your utensils enter the metal. Feeding into the stock directly creates an effect like hitting the cutting edge with a hammer. Instead, you need to glide in softly. For this to happen, generate a tool path that arcs your tool into the material rather than entering it in a straight line.
During thick-to-thin milling, the tool path entry arc should follow the same direction as the tool’s rotation. The arching entry path enables a gradual cutting force increase. What this does is prevent tool instability or snatching. Chip creation and heat generation gradually increase as well. They do so until the tool is completely engaging in the cut.
Ending on a chamfer
Massive changes in force can happen at the tool exit too. Thick-to-thin cutting is useful. But, the issue with this strategy is that thick-to-thin formation halts suddenly. It happens when the tool reaches the end of the pass and begins clearing the metal. The abrupt alteration creates a similarly abrupt change in force. It shocks the utensil and could mar the part surface. To stop such a sudden transition, first mil to a 45º chamfer at the end of the pass. Doing so will permit the tool to experience a gradual decline in the radial depth of cut.
Rely on secondary relief
A sharp edge lowers cutting forces with titanium. It must also have enough strength to resist cutting pressure. A secondary relief tool will manage to accomplish both of these objectives.
Secondary relief is a common thing with tooling. With titanium in particular though, you may want to experiment with certain utensils. These are ones that have differing designs. You could experience some surprising changes in tool life or cutting performance.
Start shopping with us for titanium grade 5 (6AL4V) plate/sheet
At Brindley Metals, we provide a comprehensive experience to all our customers. Besides offering materials, we also arrange for services like machining, polishing, and more. It means our clients can get more out of working with us. Plus, we are fast with deliveries, with same-day available in some cases. There is no minimum order here either.
So, please let us know if you need titanium grade 5 (6AL4V) plate/sheet merchandise. We can even advise you if you are unsure on sizing or other key details.