Product Description:
LIGHTWEIGHT AND STABLEOptimized machining of honeycomb sandwich panels for the aerospace industry
Lightweight construction is growing inexorably, especially in the aerospace industry. LMT Onsrud – a member of the LMT Tools group – has adapted its range of tools to meet new demands and market requirements, and now offers tools for almost every application involved in machining honeycomb panels.
Generally speaking, two kinds of honeycomb panels are used to build aircraft, and these exhibit different strength properties because of the different areas in which they are used. Structure panels, as they are called, are used in the outer skin of aircraft, and inner panels are used to build galleys and storage surfaces. For these two applications, LMT Onsrudhas developed specialized T-slot cutters (series 34-000) and insert cutters (series 34-100). These tools are characterized by variable cutting heights and replaceable cutting edge parts. They allow you to manufacture complete components with minimum tool expenditure.
The T-slot cutters are unique in that they can cut through the cover layer and undercut the honeycomb structure in one step. They consist of an indexable nib of 22.3 mm diameter, and a 12.7 mm holder coated in PCD. The difference between the two diameters produces a cutting edge overhang of 4.76 mm on each side, meaning that the edge of the cover layer is effectively undercut by 5 mm, thus opening up the neighboring honeycomb cell to the run of the cut. The undercut is then treated with a grouting compound and allowed to harden.
Using another LMT Onsrud tool, the PKD 2 cutter (series 68-000), the cover layer and honeycomb structure are cut in a single step, producing a component which in terms of its quality is then ready for installation.
The insert mills produce a drilled hole of the size of the attachment element involved. With an offset shaft, they can also be used to produced holes with an under- cut, into which the attachment elements are cast. After insertion from one side, these attachment elements are filled with grouting compound via a hole in the insert, and vented via a second drilled hole so that the hollow space created by undercutting is completely filled.
The insert mills are made in different heights for special standard panel thicknesses, such as 6.35 mm, 9.50 mm, and so on. Several removable cutting bodies are available for the T-slot cutters, in a range of thicknesses for different core thicknesses.
Both of the standard tool systems described here can be used for all cutting depths, in conjunction with custom core heights. Special tools are also produced to customer requirements.
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