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CINCINNATI—A
TOSHULIN vertical turning lathe (VTL) played an important role recently
in the creation of a revolutionary new process for removing metal
from aircraft engine spools.
The
new process, developed by Greenleaf Corporation and Pilsen Imports
for an East Coast aerospace manufacturing plant, resulted from the
plant’s efforts to reduce machining operations and cycle time.
After determining that its existing equipment was too old to produce
its spools efficiently, the plant purchased two new TOSHULIN VTLs,
which they dedicated to the design of their new metal removal process.
The company employed Greenleaf to help engineer the new process
and asked Pilsen to build the custom machines and tools required.
“No
machine existed at the time that could do what the customer needed
it to do,” says Greenleaf engineer Paul Daoust, “but TOSHULIN
and Pilsen were able to customize a machine to get the job done.”
Greenleaf
fitted the ram head tool holders of each machine with ceramic whisker
inserts that remove metal faster and cleaner than traditional cutting
inserts. Pilsen and TOSHULIN provided a ram large enough and with
the high rigidity necessary to support the redesigned tool holder.
Each machine was then equipped with separate 150-PSI and 5000-PSI
coolant systems, supplied by Pilsen, which cool the cutting tip
during the machining process. The 5000-PSI ChipBLASTER and the 150-PSI
TOSHULIN system disperse coolant onto the tip from opposing directions,
ensuring a constant temperature and chip removal during cutting.
To date, the new process has delivered a metal removal rate of 25.27
cubic inches per minute—the highest rate in the plant’s
history.
“It’s
a combination of rigidity, cooling of the tool tips, and the tools
used to increase chip removal that makes this process successful,”
says Tom Whittington, Application Engineering Manager for Pilsen.
The
new process has also significantly reduced the number of hours required
to operate the machine. The new machine provides the rigidity to
support a _-inch-wide groove tool running at 800 SFM, a feed rate
of .0035 IPR, and a material hardness range in the scale of 42 Rockwell/C.
“That
machine is running at 42 percent motor load,” says Mr. Daoust.
“That says a lot for the machine’s rigidity and how quiet
it runs. The power is awesome. You tell anyone you’re machining
Inconel 718 at that rate, and they’re going to be impressed.”
Pilsen
will demonstrate its machine customization capabilities, as well
as its solution- and application-driven sales approach, to interested
attendees at IMTS in Chicago, September 4 – 11. To learn more
about Pilsen Imports, Inc., and TOSHULIN a.s., visit www.pilsenimports.com.
Pilsen
Imports—Your Vertical Turning Machine Specialists
Pilsen Imports is a leading supplier of vertical turning equipment,
specializing in the installation, service, and support of TOSHULIN
vertical turning machines. Pilsen’s highly skilled machine
specialists have an average of 23 years experience in the machine
tool industry. We are dedicated to providing our customers with
24/7 service and support, including overnight delivery, phone and
on-site support, and comprehensive operators’, programming,
and maintenance training for every machine we sell.
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