aerospace

Competence in titanium

Starrag provides machines, tools and process expertise in economical titanium machining – all from a single source

Aircraft are constantly further developed and improved in order to meet requirements in terms of lower fuel consumption and reduced noise emissions. A clear  trend here is increasingly complex and lightweight aircraft components, whether large structural components for the fuselage or turbine elements such as blades, blisks and casings.

Turnkey planning and installation of production facilities A competence centre for titanium machining is located at the headquarters of the Starrag Group of companies in Rorschacherberg (Switzerland), which is also the home of the Starrag product brand. The first machine tools were already being built there in the early 20th century; the aviation industry is one of the municipality’s core markets. 

- 50 % shorter machining time (single- vs. double-spindle machine)

The current Starrag product line includes machine types in the STC and BTP series for titanium machining, as well as the NB centres that specialise in blisks (also titanium), and the LX series, which was developed for the simultaneous 5-axis machining of turbine blades. However, Rainer Hungerbühler, Sales Director of the Starrag Group, points out that Starrag’s competence cannot be seen simply in terms of machines, but also applies to the whole machining process: “We have various specialist teams who deal with all facets of machining and components associated with machining”. On request, Starrag produces its own VHM milling tools and carefully selects the appropriate tool holders. Even special CAM software is being developed in Rorschacherberg to enable efficient programming for users. “Ultimately, the customer does not only need a good machine”, stresses Rainer Hungerbühler. “All these components must be in harmony with one another to achieve truly effective, reliable production. In the end, feed rates and spindle figures are not so important; what really count are the unit costs that can be achieved.

“In the end, feed rates and spindle figures are not all that important; what really count are the unit costs that can be achieved”

The reliable, cost-efficient machining of titanium alloy components,such a s those used in aircraft construction, requires specially adapted machines and tools as well as a great deal of experience. The Starrag Group has been involved in machining such highstrength materials for a number of years now. On request, the titanium specialists will put together an application specific turnkey package, consisting of special Starrag STC, BTP machines or others, and also containing adapted tools, software and process expertise.

Stable basis for heavy-duty machining

- 20 % lower tool costs due to best possible damping and stable processes

The highlight of the last customer event on the topic of titanium was, without doubt, the double-spindle BTP 5000/2 profiler – already the third machine of this type, which was built on behalf of a British aircraft manufacturer. They gave their permission to show this 240 ton Big Titanium Profiler to interested parties. The BTP series was developed for the high-quality machining of particularly long and complex titanium components. Accordingly, the machine beds, guides and spindles ensure optimal stiffness and damping. The double-spindle BTP 5000/2 is almost twice as productive as the single-spindle variant that is also offered. This is because it enables two titanium structural components, up to five metres long, to be machined simultaneously.  The machine has a vertical pallet of4,5 m × 1,8 m and two 37 kW geared spindles with a maximum torque of 940 Nm to 1,300 Nm and a maximum speed of 5,600 rpm or 8,000 rpm. Reinhard Fitz, Sales Consultant for the Starrag Group explains: “With an insert mill, we can demonstrate massive cuts on such a BTP, with a volume of up to 760 cm3  per minute in TiAl6V4, with no unstable conditions arising. However, these are not values for a production facility where the profitability analysis would not warrant it. This is because the tool wear is enormous with high cutting parameters.”

Experience titanium machining live Watching, listening to and feeling the double-spindle BTP rough machining and finishing customised titanium components is remarkable. Nevertheless, there is also a complete process devised by Starrag that ensures the highest possible machine availability and precision. Only in this way can demonstrable benefits be achieved for the customer over a long production period, and customers appreciate that. This also explains the great interest in the event. 

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