Guhring 3D-printed PCD
tooling has slashed
tooling costs and
boosted productivity at
XCEL Aerospace for this
component. Inset: close-up
of cutter & part
Fine
prints
3D-printing is playing its part in helping deliver both high performance
metalcutting tools and custom press brake tooling. Machinery has
the details
XCEL Aerospace is a subcontract
manufacturer working closely with
companies like Rolls-Royce, Collins
Aerospace, Safran, Bombardier, ITP Aero,
Marshall and Incora. Offering services from
CNC machining, fabrication, assembly,
additive manufacturing, kitting and even
its own range of braided leads, the Essexlocated
manufacturer is an integral part of the
supply chain for many aerospace OEMs.
The Romford-headquartered rm invests
heavily in latest technology and innovation to
ensure cost-effective manufacturing of high
quality precision components. As part of this
drive to ensure cost-effective manufacturing,
the ADS, BSI, WEAF and SiG member invited
Birmingham-based tool manufacturer Guhring
( www.is.gd/ujigoh ) to review the machining
process for an aerospace valve component.
The problem for XCEL was excessive cost
when using existing Woodruff-type cutters to
machine a cast aluminium component having
9% silicon content.
The previous solid carbide Woodruff cutter
consisted of three teeth on a 21.7 mm
diameter tool, which was both expensive and
delivered relatively poor tool life. Only capable
of cutting 10 components before tool
replacement, the abrasive high silicone
content aluminium was creating productivity,
cost and surface nish issues for the
aerospace expert. With two batch types, the
Essex manufacturer is machining over 100
parts per month of this long-term project –
a gure high enough to cause concern over
tool life and productivity.
Invited to investigate the situation by
XCEL’s engineering and machine shop
manager, Alan French, Guhring’s regional
sales manager, Dewar McKinlay, offered an
innovative solution. Says McKinlay:
“We explained to XCEL that Guhring has a
new method of manufacturing PCD tools by
printing them on a MarkForged Metal X
3D-printing machine.
“We made the point that the bene ts were
the rapid production time in manufacturing
these tools. Additionally, this method gives
us the design exibility to produce any tool
design we desire. Firstly, we printed a plastic
tool to demonstrate the 3D-printing concept
tool to the customer. We then made a three-
ute tool that was similar to the current tool
but with brazed PCD tips. Despite the PCD
tips lasting considerably longer on the
abrasive high silicone aluminium than the
previous tool, we wanted to go further.”
The design exibility Guhring now has with
its 3D-printing facility supplied by Mark3D UK
( www.is.gd/yinusu ) enabled the company’s
TOOLING 3D-PRINTING BENEFITS
engineers to internally develop an enhanced
design within a matter of weeks. The new
design increased the number of cutting
edges from three to ve, allowing XCEL to
increase the feed rate and signi cantly
reduce production times, while at the same
time extending tool life.
Manufactured from H13 tool steel, the
tool body of the 3D-printed Woodruff cutter
has a 13 mm diameter shank with a 70 mm
overall length and the identical 21.7 mm
diameter at the cutting edge. Performance,
cost and productivity improvements have
been delivered, as Guhring’s McKInlay
explains: “This aerospace part is a longrunning
project for XCEL and we have
increased tool life beyond comprehension.
The previous solid carbide tool was worn and
required a changeover after 10 parts; we
have machined more than 180 parts with our
new 3D-printed PCD Woodruff cutter and it is
still performing well. This is giving the
customer a signi cant tool cost saving whilst
reducing the down-time and inconvenience of
changeovers.”
Stratasys suggests 3D-printed plastic
press brake tooling has a place, p26
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | September 2020 25
/ujigoh
/yinusu
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