Manufacturing tools for special operations

# Manufacturing tools for special operations

The manufacture of tools for special operations is based on highly technical processes that meet the requirements of performance, precision and durability. These tools are often used in complex industrial environments such as aeronautics, automotive, or energy. This article looks at the different stages of manufacture, the materials used, and the technological advances in the design of these tools. It will also emphasize the importance of tailoring tools to the specific needs of each application.

# Design of tools for special operations

Designing a tool for special operations starts with a thorough analysis of the industry's needs. For example, in high-speed machining (HSM), it is crucial to consider the strength of the materials, the durability of the tool, as well as the tool's ability to maintain precise tolerances under extreme conditions. Take the example of the milling cutters used in aluminum machining. This material, while lightweight and malleable, can pose challenges in terms of chip evacuation and heat management. Thus, the cutters must be designed with specific geometries to optimize chip evacuation while reducing tool wear.

In the case of the Ø58 cutter in three HSC sizes, intended for aluminum, the objective is to maximize performance on high-speed machines while minimizing the deformation of the workpiece. This type of milling cutter can be used to machine pockets in forged preforms, as shown in the example of machining 7010 aluminum. These cutters, suitable for lightweight yet strong materials, are designed to maintain a high cutting speed without compromising cutting accuracy.

# Materials used in tool manufacturing

Tools for special operations are made from high-quality materials that can withstand the mechanical and thermal stresses generated during machining processes. The choice of material depends largely on the application and the type of material to be machined. For HSC tools, solid carbide is often preferred because of its hardness and wear resistance. Carbide is a material composed of tungsten carbide particles bonded by cobalt, providing excellent performance in high temperature cutting environments.

The tools can also be coated to extend their life and improve their performance. Common coatings include titanium nitride (TiN) and titanium aluminum nitride (AlTiN), which increase wear resistance and reduce friction during the cutting process. These coatings also help keep cutting edges sharp for longer, which is crucial in high-speed operations like HSC.

# Technological advances in the manufacture of special tools

Technological advancements play a vital role in improving the manufacture of tools for special operations. One of the most prominent recent innovations is the use of additive manufacturing (3D printing) in tool design. This technique makes it possible to produce tools with complex geometries that would be impossible to achieve with traditional machining methods. For example, milling cutters and other cutting tools can be designed with internal cooling channels, optimizing heat management during the cutting process. In addition, additive manufacturing makes it possible to reduce production times and adapt tools to very specific applications.

Another area where technology has made progress is computer-aided simulation (CAD). With this software, it is possible to simulate machining conditions even before the tool is manufactured. This allows engineers to test different designs, evaluate tool performance under various conditions, and predict potential points of failure. These simulations help optimize tool geometry, reduce wear, and improve the overall efficiency of the machining process.

# The importance of adapting tools to specific operations

A specialized tool is only effective if it is well suited to the application for which it is designed. In the machining of lightweight materials such as aluminum, for example, it is important that the cutters are not only able to cut accurately, but also effectively manage the heat generated during machining. HSC cutters are specially designed for this type of material. Their geometry optimizes chip evacuation, while the materials and coatings used reduce tool wear and maintain high performance over the long term.

Adapting tools to the needs of different industries is crucial to ensure optimal performance. For example, milling cutters used in the automotive industry must meet very specific requirements, especially in terms of precision and speed. In this industry, machined components are often complex and must be mass-produced, which requires reliable and durable tools.

# Real-world customer cases

Machining in the aerospace industry with the Ø58 cutter

In the aerospace industry, the Ø58 cutter in three HSC sizes is widely used for machining aluminum parts, especially for lightweight but strong structures. For example, Airbus has integrated these cutters into its manufacturing processes for the machining of pockets in 7010 aluminum forgings. This has resulted in a significant improvement in production cycles and a reduction in machine downtime due to the efficiency of high-speed machines. The specific geometry of the cutter allows optimal chip management, thus avoiding overheating and deformation of the parts.

Precision automotive machining at a major manufacturer

In the automotive sector, a manufacturer like BMW uses HSC milling cutters for the machining of aluminum engine blocks. Thanks to the efficiency of the Ø58 cutter, production cycles have been optimized, while ensuring extreme precision within manufacturing tolerances. Machining lightweight materials while maintaining high mechanical strength is a key factor in improving vehicle performance, especially in the sports and electric car segments.

The manufacture of tools for special operations is a constantly evolving field. It is based on innovation, whether in the materials used, the manufacturing processes, or the design of tools. HSC cutters such as the Ø58 aluminium cutter are a perfect example of the importance of adapting tools to the specific needs of different industries. Thanks to the use of advanced technologies such as additive manufacturing and computer-aided simulation, it is now possible to produce tools that perform better, are more durable and better suited to complex applications.