Increased Safety and Productivity Through Sophisticated Tooling for the Aerospace Industry

Tooling for Aerospace

Twenty years ago the aviation industry was largely invested in using aluminum alloys. With the next generation of aircrafts imminent such as the Airbus A320neo and A350, or the Boeing 787 Dreamliner and 737 MAX, a new range of materials were needed to machine composite stacks.

When machining these difficult composites you require a tool made of high-quality tungsten carbide due to the vast difference in the properties of the different materials. This requires optimally designing the tool geometry for machining, then if needed, a suitable coating. However, to get the best results, the base material – the tungsten carbide substrate – is critical for success. Due to years of cooperation with many partners in aircraft manufacturing, we were able to gain extensive knowledge in this area.

Machining Ti / CFRP:
Our specially developed double step drills made out of EMT 100 tungsten carbide were able to meet all the requirement for machining a TI / CFRP composite without being coated. The tight drilling tolerance could be met in both carbon-reinforced as well as titanium materials.

Machining Ti / CFRP / Al:
Coated tools have been significantly improving for years. When constructing the fuselage of an A380, a diamond coated drill made of EMT 100 is used to machine the pressure bulkhead. This meant that two processes (drilling and reaming) could be replaced by a single step. With this change an addition of 140% service life was also achieved.