Aerospace-focused machine tools are evolving with the inclusion of 3D printing

By Staff Report September 13, 2024 6:31 pm

Anil Kumar, Managing Director of CERATIZIT India Pvt. Ltd shares how aerospace-focused machine tools are evolving with the inclusion of 3D printing for lighter components, AI and ML for predictive maintenance, and advanced materials like carbon composites and titanium alloys.

What emerging technologies are shaping the future of machine tools used in the aerospace sector?

Additive manufacturing is an important aspect of aerospace. 3D printing is used to produce lighter, stronger, and fuel-efficient components. This reduces material costs and production time while enhancing overall efficiency. The tools made with 3D printing can also solve the purpose of direct cooling, avoiding overheating and thus ensuring longer tool life. Our MM211-DC cutter is the latest example of a 3D printed tool.

AI and ML optimise machine tool operations, predict maintenance needs, and enhance decision-making. These technologies enable predictive maintenance, reduce downtime and extend the lifespan of machinery. CERATIZIT’s digital solutions like CERAsmart which includes ToolScope and Cockpit for monitoring and controlling the system constantly.

The development of new materials such as carbon fibre composites, titanium alloys, and high-temperature ceramics is changing the workings of aerospace manufacturing. Machine tools handle these materials for creating lighter, more durable, and heat-resistant aerospace components. CERATIZIT has 3 latest milling grades for comprehensively machining HRSA materials.

These technologies improve the capabilities of machine tools in the aerospace sector while driving innovation in the design and production of aerospace components.

How do cutting tools address the challenges of machining aerospace-grade alloys such as titanium and Inconel?

Aerospace-grade alloys like titanium and Inconel are known for their strength, heat resistance, and difficulty in machining. Cutting tools play a crucial role in addressing the challenges of machining.

Advance cutting tool grades for HRSA materials are made with carbide binding with cobalt. They also have rare earth elements known as mixed carbide to enhance tool life significantly. Ceramic is also becoming popular as a cutting material as these materials can withstand high temperatures and stresses associated with cutting. Specialised PVD & CVD grades are used to tackle the machining of difficult level-to-cut materials.

The geometry of cutting tools, including the rake angle, clearance angle, and chip breakers, is designed to optimise the cutting process. Dedicated chip breaker geometries are available for Inconel & Titanium materials.

Managing heat is critical when machining aerospace-grade alloys. Excessive heat can lead to tool wear and workpiece damage. Cutting tools are designed with coolant channels directly to the cutting edge and CERATIZIT’s MM211-DC technology is one step ahead which additionally cools flank edges.

These cutting tool advancements allow for more efficient machining of aerospace-grade alloys, ensuring high-quality parts that meet the stringent requirements of the aerospace industry.

What initiatives can strengthen the Atmanirbharta mission of manufacturers?

Several strategic initiatives can be undertaken for Atmanirbharata (self-reliance) in a production facility. Local capabilities can be enhanced, dependency on imports has to be reduced, and building a robust and sustainable manufacturing ecosystem can help.

Skill development and workforce training include training and development programmes to upskill employees which can build upon Atmanirbharta. Manufacturers need to strengthen their local supply chain by investing in building and supporting domestic suppliers for reliable and quality supply of raw materials.

Quality and standard enhancements can be done by continuous improvement programmes. Promoting indigenous product development can lead us to a global level from local.

By focusing on these initiatives, a production facility can move towards Atmanirbharata, contributing to a stronger, self-reliant industrial base that can compete globally.