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Workshop on titanium machining for aeronautic sector
From the European perspective, worldwide titanium demand is increasing significantly in fields such as automotion, medicine, electronics, biotechnology... but it is in the aeronautic sector where titanium consumption has grown more in recent years.
However, the difficulty to process this material through forming and, of course, machining, leads to a continuous need for research of processing improvements to increase productivity
The workshop goals are:
Present an overview of titanium alloy application trends in aeronautic sector, emphasizing the future requirements in titanium machining.
Give a scope of the problems faced when machining titanium alloys, exhibiting solutions taken in specific application cases.
Show with experimental demonstrations the viability of the studied theory.
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Stability in machining
echo $texto ?>Talks will be given by internationally renowned researchers with a contrasted experience in the machining of titanium alloys
Likewise, some demonstration trials will be carried out by two titanium machining expert technicians at Mondragon Unibertsitatea workshops. Both scientific aspects and industrial application tests will be shown.
Finally, commercial sessions will take place during the coffee breaks and lunch time where different companies will present their products related to titanium machining. The conference aims to be a forum where companies can be in the loop on innovations in the titanium machining world and find collaborative partners.
Mr. David GAUDILLERE
Mr. D. Gaudillère, in charge of hard metals machining, methods and research activities, by AIRBUS, in Toulouse - Saint Eloi Site. Master’s degree in mechanics (ENIT / Ecole Nationale d’Ingénieurs de Tarbes, 1998).
He has developed and industrialized innovative processes for AIRBUS wing to fuselage assembly (Adaptive corner fitting fettling, 2000-2003, A320, A330, and A340, Wing-to-fuselage-assembly-station in Toulouse). Today in close relation with design office requirements to set up new technology/processes allowing new concepts/materials industrialization (consequences of composite material integration in hard metal subassembly, technological watching for Hard metal machining improvements …).
Conference: Machining Titanium at Airbus. Current needs and Future trends
As a counterpart from recent composite material introduction into Aircraft structure, we find nowadays more and more titanium/hard materials on AIRBUS aircraft structures (up to 15% of an A350 aircraft weight vs. 5% of an A340). Previously mainly located around engine area, titanium solutions are now chosen for a wide range of new applications on the whole aircraft structure.
The machining of hard materials challenges with High potential of development and high complexity... and significant costs. The key driver to keep the control on costs from titanium/hard materials use, is to Improve the buy to fly ratio, and be in a position to challenge the monopole of forging suppliers and low cost manufacturers with alternative, high technologic processes.
As a consequence of this, challenges are numerous and will be detailed during the presentation.
Mr. Yvon MILLET
Presently Director of Research and Development Europe for Timet. Graduate from Ecole Nationale Supérieure des Mines de Paris, Metallurgy, he started in 1983 in Cezus Research Centre working on metallurgy and transformation of Ti and Zr alloys.
He spent several years in manufacturing and development of tubes. Started to work for Timet Savoie in 2000, as Director of Quality and Technology. He is well experienced in elaboration and conversion of titanium alloys.
Timet This is a world leader in the manufacture of semi finished products in Titanium alloys. Annual turnover 800+ M$, production 15 000 mt. Timet has production plants in the USA, UK, France and Italy. The main activity is aerospace business, leader in Ti alloys for engine. Workforce of 2300 persons including 30 in the Research Centre.
Conference: Titanium alloys: manufacture and use
Titanium alloys are been developed since 1950s. Their use has been pushed by Aerospace business, and the new programs like B787 and A350 will increase the need for such material. We propose to review the different families of alloys with their heat treatments, main manufacturing processes and best practises. Recycling is also important due to Buy to Fly ratio typically at 10.
Dr. Felix Le Maitre
Professor Dr-Ing Félix LE MAITRE
Honorary Member of the CIRP (The International Academy for Production Engineering).
Past President of CIRP 1995-1996.
Vice-President of the Scientific Council of the French Titanium Association.
Chairman of the Technical Committee “Cutting” of the French Titanium Association.
Conference: Chip formation and tool wear in titanium machining. Lubrication. Security
It will be presented the connection between the chip form during the titanium alloys machining, and the mechanism of carbide tool wear. According to the cutting conditions the chips can be continuous, segmented, or sheared (separated). These forms have an influence on the tool life, and will be discussed. The influence of the lubrication will be explained for conventional lathe turning and milling. It will be presented the risks of fire with the chips of titanium and alloys, and the incendiary conditions in workshops, and also, the risks of micro contacts according to the size of the pieces.
Dra. Ainhara Garay
She has a Science PhD (materials specialty) and nowadays she is the machinability responsible in the high performance cutting line of Mondragon University. She has a great experience in material characterization and the use of high advantage techniques of cutting parameters characterization In the last years she has participated in relevant papers based on the scientific study of machinability of different materials (steels, titanium, Inconel 718…), in industrials works directly with companies too and PhD management in this knowledge area.
Dr. Mikel Armendia
He has recently obtained the doctorate degree in Mechanical Engineering after defending his thesis about machining of titanium alloys carried out in the High Performance Machining research group of Mondragon University. This work has been spread through impact factor publications and presentations in both national and international conferences that corroborate his knowledge in machining of titanium alloys and his experience handling advanced techniques to analyze the cutting process (infrared thermography, piezoelectric dynamometers, high speed filming camera…).
Conference: Fundamental study of the machinability if the titanium alloys in turning process
This presentation will show the titanium alloys behavior during turning process. An important characterization of the alloys will be done and some results in V15 tests will be showed to illustrate the different machinability of the studied alloys. The reason of this different performance in the machining process has wanted to be explained measuring temperatures with thermography infrared camera, cutting forces, chips, tool wears, wear mechanism,… The aim is to find a connection between machinability and some variations in values of scientific and industrial parameters of machining process.
Dr. Pedro Arrázola
Pedro J. Arrazola Arriola, head on the Machining Laboratory at Mondragon university, is a Doctor of Engineering (École Centrale de Nantes, 2003) with extensive experience in researching machining operations, as much from an experimental point of view as from a modelling point of view (including numerical, analytical and empirical). With numerous publications in journal and congresses and the participation in several scientific and industrial projects he has a broad knowledge in machining processes: turning, drilling, milling, grinding… During last year’s he has focused his research in the machining of aeronautical applications (Surface Integrity when machining Inconel 718, Machinng New Beta Ti alloys, Drilling of Ti/CFRP stacks...).
Conference: Drilling and milling of the Ti6Al4V alloy
In this talk the experimental work for Ti6Al4V alloy in drilling and milling process will be presented. Results on COM tests and end tool life have been done to delimit and define the optimum machining conditions for this alloy: working conditions, tool geometry and the optimum strategy (pocket machining). The aim of this research work is to achieve an important cost reduction, guaranteeing the excellent quality of the process.
Dr Sam Turner
The head of the Process Technology Group at the Advanced Manufacturing Research Centre (AMRC) and has worked with the AMRC since its foundation in 2001 on machining technologies, growing the group to 50 strong. Since this time, Dr Turner has undertaken research in to machining dynamics, titanium and nickel alloy machining, machine tool adaptive control, cutting tool design and machining strategies. The research, sponsored through EPSRC, TSB, EU FP6, FP7 and industry, has been recognized in industry as delivering step change technologies. Dr Turner has over 10 peer reviewed journal and conference papers on machining technology and has extensive experience of applying this research to industrial projects and uses this experience to focus on the significant gaps within the current fields of research that will have step change impact on future production processes.
Conference: Titanium Machining Dynamics
The increasing demands on performance in the aerospace industry lead to a number of new challenges when machining aerospace components. The drive for higher strength to weight and high temperature performance often mean that the very properties that make these alloys desirable also make them difficult to machine. The increased cost in raw materials such as titanium, nickel and high strength steel alloys leads to a drive to nearer net components which again bring their own issues.The challenges when machining titanium alloys are driven by excessive tool wear at high surface speeds. The relatively high cutting force coefficients for titanium and the limitations on surface speed mean that high speed stability lobes cannot be achieved and that chatter stability is also a common limitation on performance with stable milling parameters limited to zones 1 and 3 in figure 1.
A strategy is presented here to identify the dominant high frequency and low frequency modes of vibration within the machining system and apply strategies and techniques to avoid chatter, using modal analysis and stability lobes for the structural modes and process damping and special tooling design for the higher frequency modes.
Dr. Erhan Budak
BSc.( 1987) and MSc. (1989) in Mechanical Engineering from the Middle East Technical University, Ankara, Turkey.
PhD. (1994): Manufacturing Research Lab. at University of British Columbia, BC, Canada. Thesis on Mechanics and Dynamics of Milling Thin Walled Structures.
1994-2000: Manufacturing Development Engineer, Pratt and Whitney Canada, Montreal Canada (machining operations, titanium machining, 5 axis milling, force control and chatter suppression in compressor machining, high speed milling of Al alloys etc. )
2000-: Sabanci University, Istanbul, Turkey Faculty member and director of Manufacturing Research Lab.-MRL (http://fens.sabanciuniv.edu/mrl/) Also general manager of the spin off company Maxima. (www.maksima.com.tr).
Conference: Improving Productivity in 5-Axis Milling of Titanium based Turbine Engine Compressors through Process Modeling
Turbine engine compressors made out of titanium alloys are among the most difficult parts to be machines due to complex geometry, thin blades causing high deflections and vibrations, tight tolerances and low machinability of these alloys. Depending on the complexity of the blade geometry, flank milling (deep immersion) or point milling method can be used in machining of these parts each having different advantages and limitations. In general, the productivity in these operations is limited by chatter vibrations, high cutting forces, part and tool deflections in addition to high rate of tool wear. In this talk, the methods developed for improved productivity using modeling and measurement methods will be presented. Increased productivity and part quality through chatter suppression, milling force control, optimal cutting strategy and process parameter selection, and tool design will be demonstrated with some examples. Simulation results with applications using the developed 5-axis milling software will also be presented.
Other published reports about International Events and Exhibitions Aerospace Sector
SITA: The 2012 Air Transport IT Summit, 20-21 June 2012, Brussels (16/04/2012)
Conference in Cardington (Bedford, UK) based on Spanish aeronautic history, 30th June 2012 (12/03/2012)
Conference in London based on Spanish aeronautic history, 15th June 2012 (12/03/2012)
V WALA Conference, Amsterdam 2012 / V Conferencia de WALA, Amsterdam 2012 (29/12/2011)
Come and visit the SITA Booth at Ground Handling International Nov 28 - Dec 1 (14/11/2011)
South Europe Airport Forum, 23th September, Rome -Italy, hosted by SITA (26/05/2011)
Future of aviation: 'Flightpath 2050' report presented by Commissioner Siim Kallas at the 2011 Aerodays in Madrid (01/04/2011)
Students Welcome Session in Aerodays 2011, 29th March at ETSIA (23/03/2011)
RAeS event: Gagarin Event - Only one week to go (10/03/2011)