Cutters to take off - With AEROLONG and AEROFINISH, Safety presents two high-performance milling cutters for the aerospace industry

Safety at the EMO in Hannover from September 19th to September 24th: Hall 6, Booth A36

(PresseBox) ( Rodgau, )
The French precision tool manufacturer Safety presents a double feature of milling cutters for fuselage and landing gear manufacturing in the aerospace industry: the long edge milling cutter AEROLONG and the fine finishing cutter AEROFINISH.

Its close pitch makes the new AEROFINISH perfect for fine finishing. The tool bodies are available in two versions: an arbor cutter and a shank cutter with Morse taper. Safety's specially developed SideLok(tm) clamping system (see below) allows for up to twice as many inserts in the tool, thus more cutting edges can concomitantly process the work piece. The table feed rate can be reliably increased up to 50%, dramatically increasing the cutting rate. The completely ground SCKR inserts (4 cutting edges) achieve, thanks to their optimised insert, geometry with large radius and finishing chamfer, an excellent surface quality of Ra < 1.6 µm. A very precise 90° edge on the inserts provides for the production of precise walls when cutting recesses. Inserts are available in sizes 4 mm and 6 mm radius, with milling bodies with diameters from 32 mm to 88 mm ex stock. As cutting grade, 5020 carbide is used, a PVD-TiAlN-TiN coated grade with excellent wear resistance and high heat resistance.

AEROLONG makes full use of its strengths particularly in peripheral milling of high shoulders, digging and contouring, as well as in both roughing and pre-finishing. According to the manufacturer, in contour milling of an engine support (titanium alloy Ti6Al4V) thanks to the number of its teeth the shell end cutter was able to successfully hold its ground even against full-carbide cutters. The thick, rugged four-edged inserts did not have to be replaced during the whole processing. In practice, processing times can be reduced by more than 20 %. For conventional milling applications the AEROLONG is equipped with precision-sintered indexable inserts and for pre-finishing a peripherally ground insert is offered. The new 5050 carbide grade with PVD-TiAlN coating makes the long edge mill a universal tool in the aerospace industry for machining materials from iron to stainless steels and titanium materials. The optimum combination of cutting grade and tool makes service life times plannable, even under the most difficult conditions such as pocket milling with long overhangs, insufficient work piece clamping or long, interrupted cuts. Long tool life time even in difficult-to-machine materials is made sure by the stable nature of the tool body. In addition, the inserts are provided with a shoulder, so in case of fracture the milling body will remain undamaged. The AEROLONG is available in diameters from 40 to 80 mm.

Revolutionary ICP clamping system allows for closer pitch cutters

With precise cutting geometries and innovative high-performance cutting grades, the two new cutters already provide excellent durability. Nevertheless, in the processing of titanium materials and Inconel(tm) chip thickness prevents cutting speed from being increased indefinitely. The key to higher feed is closer pitch. To place even more teeth on the tool body, Safety has developed the new, patented insert clamping system SideLok(tm) for inserts. Thus the number of teeth can be increased and more inserts share the load. The rigid insert clamping systemI is more stable and offers up to twice as much space for inserts in the tool body. The increased number of teeth offers significantly higher table feed (vf), decisively affected by the feed per tooth (fz) and the number of teeth (z) - which also increases productivity by up to 50 %. Even set-up times are markedly minimized by the clamping system: Without loosening the screws completely, the ICPs can be indexed very easily, worn inserts are replaced quickly.

For targeted removal of the process heat, cooling lubricant is used. Using SideLok(tm), it can be passed directly through the clamp screw to the cutting edge. Via an internal coolant supply, each insert is connected to the cooling system. The optimum cooling of the cutting edges reduces early cracking and abrasive wear on the inserts. The optimum heat dissipation also reduces crater wear.

Fig. 1: Holger Rabe, Managing Director of Safety Germany
Caption: "Aerospace is one of our key industries; with our new close-pitch cutters we achieve higher productivity and process reliability."

Fig. 2
Caption: Standard tools optimally adapted to the machining of high-strength and heat resistant materials: AEROLONG shell end mill and AEROFINISH fine finishing cutter (from left)

Fig. 3
Caption: Pocket milling is one of the most common machining operations in the aerospace industry. To this end, Safety has now started offering the new AEROLONG and AEROFINISH cutters.

Fig. 4: SideLok(tm)
The innovative SideLok(tm) clamping system allows up to twice as many inserts to be mounted in the tool, thus more cutting edges can concomitantly process the work piece. The table feed rate can be reliably increased up to 50%, dramatically increasing the cutting rate.

Safety, Rodgau: Comprehensive tool solutions - competent, flexible and fast

Safety, established in France in 1932, is an international manufacturer of precision tools for the metal cutting industry. The traditional company that employs about 500 employees all over the globe counts many famous names from the fields of Automotive, Aerospace, Die & Mould and Energy among its customers. Based on its own quality tools, activities focus on technical support and comprehensive tool solutions in standard and specialized fields: Together with Safety's specialists, users can quickly and flexibly optimize their production processes, increase productivity and reduce costs. In Germany, Safety is present with a sales office in Rodgau.

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Press Contact:

Safety Germany
Michaela Haupt
Head of Marketing
Philipp-Reis-Str. 7
D-63110 Rodgau
Phone: +49 6106 268 48 15
Fax: +49 6106 268 48 22

Agentur für Public Relations GmbH
Ralf M. Haaßengier
Kalkhofstraße 5
D-70567 Stuttgart
Phone: +49 711 71899 03/04
Fax: +49 711 71899 05
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