Aerospace Solutions

Aerospace Solutions

INDEX Assembly 2 Type 3 CFRP 4 CFRP/AL Stack 5 CFRP/TI Stack 6 Special Assembly s 7 Structure 8 Aluminum Parts 9 CFRP Parts 11 Titanium Parts 13 Honeycomb Parts 17 Engine 18 Drilling & Threading 19 Milling 21 Other Parts 22 Actuator 23 Pylon 25 Landing Gear 26 1

Assembly 2

Assembly Type Hand Positioning : Manual : Feed : Manual : Pneumatic Positioning : Manual : Feed : Automatic : CNC Positioning : Automatic : Feed : Automatic : 3

CFRP High feed and long tool life & D-GDN90 Diamond Coated 90 Degree Point Angle Drill 90 Depth of Hole.25106.375 CFRP 100m/min 5,000min -1 1,000mm/min 0.2mm/rev 10mm Through Dry Vertical Machining Center (HSK-63A) Incredible coolant flow capability DIA-HO-SC-GDS Special Diamond Coated Countersink Drill with Helical -Through Depth of Hole 9.576 100Special CFRP with Copper Mesh Top Layer CFRP 150m/min 5,000min -1 670mm/min 0.134mm/rev 15mm Through Internal MQL Vertical Machining Center HSK-63A D-GDN90 Hole Exit D-GDN90 Flank Hole Entrance Number of Holes 300 600 900 1,200 1,500 500 Holes 1,500 Holes Margin Hole Exit Hand Pneumatic CNC 1,000 Holes Still Running 1,500 Holes Cutting Edge and Holes After Drilling 450 Holes 450 Other Parts Engine Sutructure Assembly 4

Assembly CFRP/AL Hand Pneumatic CNC Internal MQL Internal Air Incredible coolant flow capability DIA-HO-SC-GDS Special Diamond Coated Countersink Drill with Helical -Through Cutting Method 9.576 100Special Internal MQL CFRP/AL Stack Vibration Assisted Drilling Internal Air 150m/min 5,000min -1 80m/min 2,660min -1 500mm/min 0.1mm/rev 266mm/min 0.1mm/rev Vertical Machining Center HSK-63A Chip Shape Comparison Vibration Assisted Drilling Conventional Drilling Coupon Hole Entrance CFRP 7mm A7075 6mm Hole Exit 5

CFRP/TI One-shot drilling for stacks STCH-D Special High Helix Diamond Coated Drill for Stacks Cutting Method 6.375 Special CFRP / TI Stack Vibration Assisted Drilling 20m/min 1,000min -1 50mm/min 0.05mm/rev Internal MQL Vertical Machining Center HSK-63A For improved surface quality DIA-O-ENC Special Diamond-Coated 6-fluted End Mill for Planetary Drilling 6 11 R0.6 6FL Special CFRP / TI Stack CFRP Ti-6Al-4V Coupon Hole Entrance CFRP 7mm Ti-6Al-4V 5mm Hole Exit Hand Pneumatic CNC Other Parts Engine Sutructure Assembly 150m/min 4,340min -1 50m/min 1,447min -1 1,302mm/min 0.05mm/t 868mm/min 0.1mm/t Hole Dia. 20 Ramp Angle 1 0.5 Machining Time Internal Air Internal MQL Vertical Machining Center HSK-63A 1min 24sec Coupon Hole Entrance CFRP 7mm Ti-6Al-4V 5mm Hole Exit 6

Assembly Special Assembly s Hand Pneumatic CNC Threaded Hex Shank Adapter Drill Double Margin Step Drill Nutplate Drill / Countersink Tapered Drill / Reamer Threaded Hex Shank Reamer PCD Brazed Countersink PCD 7

Structural Parts 8

Structural Parts Aluminum Parts Incredible chip removal rate AERO-ETS Short Flute Rougher 3FL Carbide End Mill with Corner Radius and Short Length of Cut 3 Depth of Cut Holder Spindle Power M.R.R. 25 R4 3FL 3 A7075 2,591m/min 33,000min -1 29,700mm/min 0.3mm/t ap=10mm ae=25mm Water-Soluble Shrink Holder 120kW 7,425cm 3 /min M.R.R. over 7,000cm³/min is achieved by spindle power of 100kW or more. 100kW 7,000cm 3 /min 9

Long Length of Cut Chattering AERO-EXTL Long Flute Wall Finisher 3FL Carbide End Mill with Corner Radius and Long Length of Cut 3 Size Depth of Cut Spindle Power 20 R1 3FL 3 A7075 817m/min 13,000min -1 5,850mm/min 0.15mm/t ap=87.5mm ae=0.2mm Water-Soluble Vertical Machining Center 15kW With prevention of chattering, high efficiency side milling is achieved in one-shot milling. Other OtherParts Engine Structural Parts Assembly 10

Structural Parts CFRP Parts Out of the ordinary performance DIA-BNC Nick Rougher Diamond Coated Fine Nick Router Comparison of Durability Milling Length (m) 20 40 60 CFRP Stringer end trim CFRP DIA-BNC 3/8" (9.525mm) Competitor (Diamond Coated) 15.7m Over 60m 60m 4 Times 4 DIA-BNC was able to achieve 4 times the durability versus the competitor. DIA-BNC4 11

Achieving stable cutting without chattering DIA-REC Roughing Rougher Diamond Coated Roughing Router DIA-REC DIA-BNC Competitor DIA-REC DIA-BNC 624 N Cutting Force (N) 500 1,000 1,500 2,000 2,500 976 N Other Parts Engine Structural Parts Assembly Dia 10 CFRP Competitor's Herringbone Cutter 6FL 6 2,211 N 200m/min 6,400min -1 400mm/min 0.063mm/rev DIA-REC DIA-BNC Competitor Herringbone 6FL Depth of Cut ap=25.4mm ae=10mm Dry Vertical Machining Center By reducing the cutting force, stable milling even under low rigidity is achieved. 12

Structural Parts Titanium Parts Strong cutter body and insert PSEL XC5040 OSG Phoenix Roughing End Mill Insert grade Depth of Cut M.R.R. 50 5FL Special ZDKT11T308ER-SM (XC5040) Ti-6Al-4V AMS4911 40m/min 255min -1 128mm/min 0.1mm/t ap=20mm ae=46mm 118cm 3 /min Water-Soluble 5-axis Machining Center (HSK-A100) 5 After Milling 1.5 hours 1.5 13

High efficiency i roughing and finishing i with one tooll 1 1 UVXL-TI-5FL Variable Lead End Mill Long Type for Titanium Alloy (5FL) 5 Roughing Finishing Process Roughing 100m/min 1,592min -1 796mm/min 0.1mm/t 20 R3 Ti-6Al-4V AMS4911 Finishing 80m/min 1,274min -1 510mm/min 0.08mm/t Depth of Cut ap=78mm ae=2mm ap=78mm ae=0.1mm M.R.R. 124cm 3 /min 4cm 3 /min Water-Soluble 5-axis Machining Center (HSK-A100) 5 Finishing Process Depth of Cut M.R.R. 25 R3 Finishing Ti-6Al-4V AMS4911 80m/min 1,019min -1 408mm/min 0.08mm/t ap=98mm ae=0.1mm 4cm 3 /min Water-Soluble 5-axis Machining Center (HSK-A100) 5 Other Parts Engine Structural Parts Assembly 14

Structural Parts New & Holder Combo UVX-TI Safe-Lock Features of Safe-Lock system Safe-Lock High runout accuracy (less than 3 m) Adjustable overhang length Easy removal of broken tools Internal coolant supply capability from the holder Also suitable for high speed steel tools 3 m The key to stability in high performance machining On the safe side with Safe-Lock Safe-Lock No pull-out of the tool Achieves maximum chip removal rate No damages on expensive work piece Ideal for large diameter milling Special grooves in the tool shank UVXL-TI-5FL Form closed drive keys in the holder by HAIMER Safe-Lock is a registered trademark of the Haimer GmbH. 15

High efficiency milling of Ti-6Al-4V with Safe-Lock power shrink chuck Safe-Lock Holder Milling Method Safe-Lock Power Shrink Chuck Safe-Lock UVX-TI-5FL25 R3 75-SL Slotting Ti-6Al-4V AMS4911 50m/min (637min -1 255mm/min (0.08mm/t) Milling Chuck UVX-TI-5FL25 R3 75 Side Milling Depth of Cut ap=48mm ae=25mm ap=48mm ae=12.5mm M.R.R. Result 306cm 3 /min No tool pull-out Water-Soluble Horizontal Machining Center (BT50) pull-out Milling direction Burr Safe-Lock Power Shrink Chuck Safe-Lock 153cm 3 /min Before milling After milling pull-out of 4mm 4mm Other Parts Engine Structural Parts Assembly pull-out occurred with the milling chuck holder under the above cutting condition. The tool paired with the Safe-Lock system, on the other hand, encountered no such issue and could be use for deep slotting of ap=48mm. Safe-Lock ap=48mm 16

Structural Parts Honeycomb Parts Evolved sharp cutting edges HBC60 60 Degree Helix Compression Router CFRP / AL Honeycomb CFRP/ Processed by Coventional Processed by HBC60 HBC60 AFRP / Nomex Honeycomb AFRP/ Processed by Competitor GFRP / Nomex Honeycomb GFRP/ Processed by HBC60 HBC60 17

Engine 18

Engine Drilling & Threading Guaranteed reliability WX-PNC Thread Mill for Non-ferrous Metal and Heat-Resistant Alloy Internal Thread Size Tapping Length Drill Hole Size 4.55 10 U28 Waspaloy 20m/min 255min -1 128mm/min 0.06mm/t ¼-28UNF for Helicoil/EG/STI 7.8 6.6 Water-Soluble Horizontal Machining Center (BT40) Gauge out after cutting 72 holes, but no chipping was found. 72GP-OUT 19

Outstanding stability WHO55-3D -Through Carbide Drills for High Hardness Steels Hole Size WHO55-3D Competitor 7 (Special) 30m/min 1,364min -1 143mm/min (0.105mm/rev Inconel 718 (45HRC) 718 7 18mm, (Through), No Pecking Number of Holes 100 200 300 400 500 301 Holes 508 Holes Chipping After Drilling 508 Holes 508 Water-Soluble (10 ) Horizontal Machining Center BT40 Wear mm 0.035 0.03 0.025 WHO55-3D Competitor 0.02 0.015 0.01 0.005 0-0.005 0 60 120 180 230 300 370 440 500 Number of Holes Hole Expansion Exceptional productivity WHR-NI-POT Spiral Point Tap for Ni-based Superalloy Ni WHR-NI-POT 5/16-24UNJF (Special) 3m/min min -1 Number of Holes 50 100 150 200 200 Holes After Tapping 200 Holes 200 Still Running Other Parts Engine Structure Assembly 20

Engine Milling Best combination PRC + XC5040 OSG Phoenix Radius Cutter Insert grade Depth of Cut PRC12R050M22-5 ( 50 6FL) RPHT1204M8EN-SM (XC5040) Inconel 718 718 30m/min 191min -1 172mm/min 0.18mm/t ap=max6mm ae=22mm Non-Water-Soluble Horizontal Machining Center (BT50) Long lasting end mill UVX-NI-5FL Multiple Length, 5 Flutes Corner Radius End Mill for Ni-based Superalloy 5 Ni Machining Time Depth of Cut 12 R1 5FL (Special) Inconel 718 718 30m/min 800min -1 110mm/min 0.027mm/t 1.5 hours ap=5mm ae=12mm Non-Water-Soluble Horizontal Machining Center (BT50) After Milling 1.5 hours 1.5 Peripheral Cutting Edge Rake End Tooth 0 21

Other Parts 22

Other Parts Actuator Long lasting end mill UVX-NI-5FL Multiple Length, 5 Flutes Corner Radius End Mill for Ni-based Superalloy 5 Ni Depth of Cut Overhang Length Holder 20 R1 5FL (Special) 15-5PH H1025 40HRC / AMS5659 56.5m/min (900min -1 275mm/min (0.061mm/t) ap=10mm ae=20mm 64mm 3.2D Water-Soluble Shrink Holder Horizontal Machining Center BT50 After Milling 10.5m 10.5m Flank Rake Max. Wear Corner 23

Incredible coolant supply ADO-SUS-3D -Through Carbide Drill Series for Stainless Steels and Titanium Alloy Depth of Hole 8 15-5PH H1025 40HRC / AMS5659 70m/min (2,785min -1 668mm/min (0.24mm/rev) 24m (Blind) No Pecking Internal Water-Soluble Horizontal Machining Center BT40 A-Tap also works well in 15-5PH 15-5PH A-TAP A-SFT HL High Efficienty Multi-Purpose Tap Series for Helicoil/EG/STI Drill Hole Size Tapping Length No.10-32UNF 15-5PH H1025 40HRC / AMS5659 5 16mm Blind 10mm 5m/min 275min -1 Water-Soluble Chlorine-Free (10%) 10 Vertical Synchronized Machining Center ADO-SUS- 3D A-SFT HL Number of Holes 500 1,000 1,500 2,000 2,500 2,500 Holes After Drilling 2,500 Holes 2,500 Wear Tapping Holes 20 40 60 80 100 100 Holes Cutting Edge After Tapping 100 Holes 100 Still Running Other Parts Engine Structure Assembly 24

Other Parts Pylon ADO-SUS also works well in Titanium alloy ADO-SUS-3D -Through Carbide Drill Series for Stainless Steels and Titanium Alloy Depth of Cut 5.1 Ti-6Al-4V 40m/min 2,500min -1 300mm/min (0.12mm/rev) 17mm Through Internal Water-Soluble Vertical Machining Center (BT30) ADO-SUS- 3D Number of Holes 500 1,000 1,500 2,000 2,500 2,066 Holes After Drilling 1,200 Holes 1,200 Flank Margin Chipping Cutting Chips Shapes Rake 0 25

Landing Gear Strong cutter body and insert & PSEL XC5040 OSG Phoenix Roughing End Mill 15R063M27-3-50 63 3FL Competitor63 4FL Insert grade ZDKT150508ER-SM (XC5040) Coated Carbide Insert Depth of Cut Overhang Length 150mm/min (0.2mm/t) Ti-6Al-4V (35HRC) 50m/min (250min -1 ) ap=21-45mm ae=7.5-25mm Water-Soluble 300mm 150mm/min (0.15mm/t) Horizontal Machining Center HSK100A The PSEL achieved 3 times longer tool life (3 workpieces and welding wear after 276 mins) than the competitor tool (1 workpiece and chipping after 92 mins). Moreover, the PSEL was able to maintain consistent chip shape and minimize the risk of sudden chipping. PSEL 3276 192PSEL 3 Other Parts Engine Structure Assembly Favorable Shape of Cutting Chips 26

International Headquarters 3-22 Honnogahara, Toyokawa, Aichi, 442-8543, JAPAN TEL : +81-533-82-1118 FAX : +81-533-82-1136 0120-4 1-5 981 FAX E-mail 0533-82-1134 hp-info@osg.co.jp Safe use of cutting tools Use safety cover, safety glasses and safety shoes during operation. Do not touch cutting edges with bare hands. Do not touch cutting chips with bare hands. Chips will be hot after cutting. Stop cutting when the tool becomes dull. Stop cutting operation immediately if you hear any abnormal cutting sounds. Do not modify tools. Please use appropriate tools for the operation. Check dimensions to ensure proper selection. Copyright 2016 OSG Corporation. All rights reserved. specifications are subject to change without notice.