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hp tooling 2021 #4

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The journal of hp tooling is an english, global publication on all aspects of high precision tools, accessories and their applications.

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World’s leading trade fair for grinding technology GrindTec 2022 15 - 18 March | Messe Augsburg | Germany | www.grindtec.de materials & tools Comparatively the most defects in 3D printed components are detected by neutrons Test procedures under scrutiny Conventional processes often reach their limits in the manufacture of turbines. Increasingly additive manufacturing is used to produce complex, curved components with intricate structures. A research team from the Technical University of Munich (TUM) has now examined common methods used to locate defects inside components. pores and cracks. Even partial or total separation of individual layers can occur. Defects in safety-critical components, such as turbine blades, can have serious consequences. “We therefore need to examine critical components after the manufacturing process and of course do so non-destructively,” explains Cara Kolb from the Institute for Machine Tools and Industrial Management at TUM. a look inside For their experiments the researchers produced test specimens with defects of different size and depth and then attempted their detection using non-destructive testing methods. This involved active infrared thermography (aIRT), ultrasonic testing (UT), X-ray computed tomography (CT) and neutron grating interferometry (nGI). At the research neutron source doctoral student Tobias Neuwirth conducted the experiments at the ANTARES instrument. “We investigate components using neutron grating interferometry, observing the scattering and absorption of neutrons in a spatially resolved manner. Changes in these properties give us information about the type and size of the defects,” he explains. copyright Bernhard Ludewig FRM II/TUM In their investigation neutron grating interferometry, performed at the Heinz Maier-Leibnitz research neutron source (FRM II), achieved the best defect detection. Laser beam melting is a common 3D printing process for turbine blades with internal cooling channels. During this process a laser melts a thin layer of metal powder in predefined areas. Layer by layer the component forms in a bed of powder. Like in an archeological excavation, the component is then exposed and the remaining powder can be reused for the next printing process. However, process instabilities can lead to defects and reduce the strength of the component. Typical defects are Greater penetration and better resolution with neutrons Each of the methods tested has both potential and challenges. Neutron grating interferometry is complex and more expensive than the other test methods investigated, but of all the methods it detected the most and the smallest defects. “Neutrons can penetrate deep into the mate - rial and resolve the internal component structure with high resolution. They are particularly suited to nickelbased alloys, which are enormously important for the additive manufacturing of structural components in aerospace,” concludes Cara Kolb. Research into testing procedures that non-destructively assure the quality of 3D-printed components is very important: such procedures reveal the likelihood of a component failure during operation. They are also ever more important as additive manufacturing, for example in aircraft and cars, increases. further information: https://www.mec.ed.tum.de/en/iwb/institute/departments/ additive-manufacturing/ 24 no. 4, November 2021

World’s leading trade fair for grinding technology GrindTec 2022 15 - 18 March | Messe Augsburg | Germany | www.grindtec.de Milling expansion for difficult-to-machine materials materials & tools Dormer Pramet has launched a new generation of solid carbide five-flute end mills, specifically for dynamic milling in general machining and die and mould applications. The company’s S7 assortment covers a wide range of operations in a variety of steels, cast irons and difficult-to-machine materials, including stainless steels and super-alloys. These latest additions, S770HB, S771HB, S772HB and S773HB, offer increased feed rates up to 25 %, compared with four-flute cutters. All feature a positive rake angle for smooth cutting action and to reduce the risk of work-hardening. An AlCrN coating provides thermal stability, reduced friction, excellent wear resistance and prolonged durability, while a small corner radius and cutting-edge design gives a stable performance and prolonged tool life. The Dormer S7 five-flute assortment covers a wide range of operations in a variety of materials The S771HB and S773HB cutters are suitable for narrow pocketing, trochoidal slotting and profiling applications. These end mills include a chip divider to break swarf into manageable smaller pieces, helping to reduce spindle load and increase metal removal rates. This provides a 50 % bigger width of cut compared to tools without a chip divider. A neck recess helps avoid contact with the wall in shoulder operations, while through coolant improves welding resistance and enables a wide range of processes, especially for difficult-to-machine materials. The S770HB and S772HB are more suitable for profiling, trochoidal slotting, and semi-finishing applications, offering maximum productivity due to optimal metal removal rate and reduced machining time. Multi-application high performance cutters Meanwhile, Dormer pramet has added three multi-application high performance cutters within its S7 range for use on both CNC and conventional machine tools. The new additions – S722HB, S765HB and S768 – support most common operations, such as slotting, plunging, contour milling, ramping and copy milling in various materials, including medium strength steels, stainless steels and super alloys. These four-flute cutters have a specific tooth design for improved chip evacuation. The AlCrN and Titanium Silicon Nitride (TiSiN) coatings support longer tool life, higher cutting speeds and increased heat resistance, making them ideal for dry machining. Finally, the global manufacturer has added a new solid carbide cutter to enhance its assortment of end mills for hardened steel above 49HRC. The S561 is specifically for high performance milling in a variety of applications, including die and mould machining. This four-flute end mill features a specific tooth design for improved chip evacuation. A sharp cutter for hardened steel (52-70HRC), the S561 offers excellent surface finishing, while a gash land to improve strength and chipping resistance. further information: www.dormerpramet.com no. 4, November 2021 25

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