The Influence of High Pressure Coolant on Process Optimization in Heat Resistant Super Alloys (HRSA)

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The Influence of High Pressure Coolant on Process
Optimization in Heat Resistant Super Alloys (HRSA)
Sean Holt Aerospace Application Manager Sandvik
Coromant
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Agenda

• Introduction and history of High Pressure
• Challenges in Machining
• Operational differences
• HPC System requirements, benefits
  considerations
• HRSA machining results difference with other
  materials
• Future trends directions

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The History of High Pressure Coolant (HPC)
500(7250)
Ccoupling for UHPC
VTL
100(1450)
Pressure bar (psi)
Multi-task Machining center Turning center
Standard coupling
1984
1990
1996
2007
2012
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High Pressure CoolantDefinitions

• High Pressure Coolant (HPC)up to 80 bar (1160
  psi)
• Standard option on most machines
• Turning centers
• Machining centers
• Multi-task machines
• Standard Coromant Capto coupling
• Standard Sandvik Coromant tools available
• Ultra High Pressure Coolant (UHPC)over 80 bar
  (1160 psi )
• Standard option for a few machine manufacturers
• Limited to VTLs
• Coromant Capto coupling for UHPC
• Tool holders only as special

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High Pressure CoolantDefinitions

• Pressure (p)Force per unit area
• Pascal N/m2
• Bar 0.1 MPa (14.5 psi)
• Flow rate (?)Volume displaced per time unit
• liter/min (gallons/min)
• Velocity (w)Speed fluid moves through a tube
• m/sec (ft/sec)

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High Pressure CoolantChallenges in machining

• Operation differences
• Turning continuous single point
• Cutting temperature
• Chip control
• Milling interrupted multiple teeth
• Chip formation
• Cutter positioning
• Re-cutting of chips unsecure or short tool life
• Drilling continuous multiple teeth
• Varying cutting temperature
• hot periphery
• tough center
• Chip control and evacuation through flute

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HPC Machining Requirements
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HPC System requirements

• Pump/machine
• Pressure
• Volume/flow rate
• Filter

• Tool
• Nozzle diameter
• Number of nozzles
• Jet flow
• Jet direction

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HPC System requirementsPrinciples

• Reducing the area increases the velocity
• Smaller outlet reduces the pressure and flow rate
  requirements to achieve a high velocity jet

Flow velocity w1
Flow velocity w1
w2
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HPC System requirementsFlow requirement

• ? Flow expressed in m3/s
• CD Nozzle efficiency
• - 80 20 to 300 bars (290-4350 psi)
• - 70 300 to 1000 bars (4350-14500 psi)
• n Number of nozzles
• d Nozzle diameter (m)
• p Pressure (Pa) - 1 bar (100 000 Pa)
  - 1 psi (6895 Pa)
• ? Fluid density - for water and cutting fluids
  the density is 1000 kg/m3

The larger the outlet area the greater the flow
required to deliver a given pressure
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HPC Machining HRSAs
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HPC Turning applications Precision is the power

• Hydraulic wedge lifts the chip
• Reduces temperature
• Improves chip control

Coromant Capto Normal coolant inlet
High precision jet nozzles
Pre-defined target areas on the insert face
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HPC Turning applications Inconel 718 (46HRC)
-Total material removed (TMR)
Insert ap fn
CNMX 1204A2-SM S05F 2.5 mm 0.3 mm/rev
CNMX 43A2-SM S05F 0.1 inch 0.012 inch/rev

• With CoroTurn HP 70 bars (1160 psi)
• Metal removal 50 at same speed
• Cutting speed 20 with same total metal removal

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HPC Turning applications Inconel 718 (46HRC) -
Chip control
Insert vc
CNGG 120408 -SGF1105 65 m/min
CNGG 432-SGF 1105 213 sfm
Normal Pressure
80 bar (1160 psi)
Cutting depth ap (mm)
Cutting depth ap (mm)








2.0
2.0
1.0
1.0
0.5
0.5
Feed fn (mm/rev)
Feed fn (mm/rev)
0.25
0.25
0.15
0.2
0.15
0.2
0.25
0.25
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HPC Turning applications Inconel 718 (46HRC) -
Demonstration
Insert ap fn
CNGG 120408-SGF 1105 0.25 mm 0.15 mm/rev
CNGG 432-SGF 1105 0.01 inch 0.006 inch/rev
CoroTurn HP normal pressure
CoroTurn HP 80 bars, 1160 psi
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HPC Machining in the Future
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UHPC Turning applications The basic concept of
the technique
Coolant inlet
UHPC
HPC

• HPC tool internal coolant supply through
  Coromant Capto polygon
• 80 bar (1160 psi)

• UHPC tool - coolant supplied externally into the
  Coromant Capto coupling
• UHPC blanks - prepared with foursealing seats
• 80-1000 bar (1160-14500 psi)

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UHPC Turning applications Effect on Inconel 718
UHPC - 230 bar (3300 psi) 3 mins
Normal coolant 3 mins
UHPC - 150 bar (2200 psi)
UHPC - 300 bar (4350 psi)
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Summary

• HPC has seen significant improvements in the last
  few years
• New technologies methods have made machining in
  HRSAs more efficient
• Benefits of using HPC in HRSA machining
• Improves chip control
• Improves tool life
• Improves cutting speeds

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