As the aerospace industry seeks faster, cost-effective, and environmentally-friendly solutions, the challenge of manufacturing zero-emissions aircraft becomes more pressing. While reducing CO2 emissions during flight remains a key focus, the environmental impact of material processing during production is equally critical, influencing production efficiency and quality.
One effective way to address these challenges is through the precise application of coolant, which can significantly enhance output, process security, and tool performance. This trend is reflected in the growing aerospace lubricants market, which is expected to expand at a compound annual growth rate (CAGR) of 19% from 2022 to 2027.
The application of coolants in machining aerospace parts has evolved considerably. Traditionally, machine shops have used coolants by directing tubes to flood the machining zone, especially for materials that require cooling during the process. However, the introduction of high-precision coolant application, where coolant is accurately directed into the machining zone, offers new benefits. This technological advancement is supported by the higher coolant-supply capacity of modern CNC machines and innovative tooling designs.
To achieve maximum effectiveness, coolant must be applied as high-precision jets, delivered in sufficient volume and accurately targeted. Simply flooding the machining area with coolant is inadequate. When applied correctly, high-precision coolant can significantly impact chip formation, heat distribution, surface integrity, and tool wear, leading to improved productivity, tool life, chip control, and component quality.
Precision coolant proves particularly advantageous when machining challenging materials like heat-resistant super alloys (HRSAs) and titanium alloys. The technology is increasingly accessible due to advancements in CNC machine design, which often include coolant supplies capable of pressures between 70 and 100 bar. This enables the effective use of high-precision coolant in various machining operations, including turning, milling, and boring.
Modern modular tooling systems, such as Coromant Capto®, facilitate the efficient delivery of coolant directly to the cutting zone, improving chip control, process security, and overall machining performance. Precision coolant also contributes to longer tool life, especially in operations that generate significant heat.
For example, in turning operations, tools equipped with precision coolant deliver accurate, high-velocity coolant jets that improve chip formation and reduce machining temperatures. This results in smaller, more manageable chips and enhanced tool performance, even at lower coolant pressures.
In finishing operations, precision coolant has been shown to extend tool life by up to 50%, allowing for higher cutting speeds without compromising tool longevity. This is particularly valuable when machining materials like titanium, where higher cutting speeds can drastically reduce tool life if not properly managed.
Overall, the application of high-precision coolant in machining operations offers significant benefits, particularly in the demanding aerospace sector. It optimizes established machining processes, ensuring shorter cycle times, consistent component quality, and enhanced process security.
Sandvik Coromant, a leader in metal cutting and machining solutions, continues to drive innovation in this field. With decades of experience and a commitment to sustainability, Sandvik Coromant is dedicated to shaping the future of machining by providing cutting-edge tooling solutions that promote efficiency and growth. As part of the global industrial engineering group Sandvik, the company is at the forefront of efforts to create a more sustainable and innovative future for the engineering industries.
