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Demand for machining titanium for aerospace applications won’t abate any time soon. It is driving OEMs and the supply chain in the commercial airplane market to find ways to dramatically increase machining output. Whatever date you pick from now until 2030, there’s a sufficient backlog of commercial airliners for both structural and jet engine applications to keep spindles humming around the clock cutting titanium.

When sizing up an application for a milling toolholder, it is necessary to consider the materials being machined, how aggressively metal is going to be removed, and any machining conditions that are likely to present a challenge to tooling security. By now, the pros and cons of hydraulic, mechanical, and heat-assisted shrink-fit systems are well known and results well documented.

A recent effort by the Norton Advanced Applications Engineering Group demonstrates that for difficult-to-machine materials, grinding can be an economical alternative to other machining processes.

Machine manufacturers are working to streamline the gear-making process, to deliver a more highly finished gear in fewer steps.

The challenge of machining hip replacement implants out of cobalt chrome

The growing need for nano and micro components in the medical industries is challenging manufacturers to continually improve upon their manufacturing processes and take a scientific approach to injection molding and tooling.

Highly realistic 3-D simulation software can greatly improve manufacturing processes, lending sophisticated visualization tools that help increase manufacturing productivity and product quality.

It’s getting harder to imagine any market that isn’t benefiting from the latest developments in parts manufactured from advanced composites. “Advanced composites will arguably dominate consumer and production products, especially in the near future,” says Bert Erdel, industry consultant and executive technology advisor, Morris Group Inc. (Windsor, CT), “as they have begun to gain wide acceptance in solving energy-related issues.”

The machining challenges for two of the most advanced concepts in cutting tool materials are pretty well known. Cubic boron nitride (CBN) tools of varying designs are being used to cut hardened ferrous metals with or without interrupted cuts, as well as welded and clad metals.

Overall, there are two overriding customer needs: reducing cycle time and machine downtime. They want higher feed rates and depth of cut for greater metal removal.