Precision tooling solutions for aerospace components

In the realm of cutting-edge aerospace applications, precision and performance are essential for transforming the toughest materials into high-flying components. Whether titanium alloys, nickel-based superalloys or advanced ceramics, these materials and the tools that machine them are the backbone of aerospace innovation. Kennametal’s tooling solutions are designed to tackle manufacturers’ challenges, helping them achieve higher precision, better surface finishes and increased productivity.
Reliance on high-temperature resistant materials presents challenges. Traditional tooling doesn’t stand a chance when used in this environment due to friction, deformation and other component failure. For example, engine parts made from titanium and superalloys must endure temperatures over 1,000°F. That’s why high-temperature machining solutions become critical. It also means that the materials being used demand more than just tough tools; they must thrive under extreme conditions.

High-Temperature Machining Goes the Distance
Components powering everything from jet engines to exhaust systems are built to withstand extreme environments. Machining these components requires tools that can perform without compromising an aircraft’s structural integrity. This is exactly where Kennametal excels, delivering tooling solutions that meet aerospace’s toughest demands head-on.

Innovative Tooling Solutions
Kennametal’s high-temperature machining tools are specifically engineered to tackle challenges such as high cutting forces, heat buildup, and work hardening. They use advanced coatings, precision geometries, and heat-resistant materials for efficient machining under extreme conditions.
Kennametal’s family of HARVI solid carbide end mills is a game-changer for machining tough aerospace materials like titanium and Inconel. HARVI™ Ultra 8X excels in airframe structural machining, while HARVI™ III is optimised for titanium applications. The HARVI I TE, with its twisted cutting edge, boosts corner stability and excels in ramping and helical interpolation. It features advanced anti-vibration and anti-friction technology. The innovative flute design with chip gashes reduces cutting forces, making chip evacuation super-efficient.

Building on the success of the HARVI series, the newly launched HARVI II TE end mills feature a 5-flute design for aggressive cutting in ramping and plunging, as well as a proprietary W-flute shape for better chip evacuation and a stronger core. Overall, the HARVI tools deliver significant time and cost savings in aerospace operations, with impressive Metal Removal Rates (MMR) and tool life.
Drilling composites like CFRP can effectively create fuselage, wing skins, and spoilers. Still, Kennametal’s KenTIP™ FS series of drills featuring a double-angle geometry is specifically designed for composites. Additionally, Kennametal offers KenShape™ MaPACS & MaxPACS and HiPACS countersink and drill solutions. These tools are engineered to handle the challenges of drilling composites, ensuring clean cuts and minimising issues like delamination and fibre breakout. By using these advanced tools, manufacturers can achieve high-quality results while maintaining the structural integrity of their components.
When it comes to precision turning, especially with tough materials, Kennametal’s Beyond Evolution™ line of carbide and ceramic inserts will be effective. These inserts are built to handle the high temperatures associated with turning operations, which are common when working with hardened steels in landing gear and other components.
Dealing with the hassle of frequent tool changes, especially when working on large components like wing sections, Kennametal’s KM™ and KM4X™ modular quick-change tooling systems come into play. They make tool changes super quickly without losing accuracy. For tasks that need high repeatability, like wing skin assembly, it’s crucial to calibrate tool holders to keep everything aligned perfectly regularly.
“Aerospace manufacturers can achieve exceptional precision and productivity with our tooling solutions, ensuring every component meets our aerospace customers rigorous demands,” said Eva-Maria Weber, Manager Aerospace Business Unit CE.
Overcoming Challenges in High Temp Machining
In high-temp machining, precision, reliability, and speed are key and always at the forefront. Sometimes, problems arise, such as in thin-wall applications, surface finishes, and milling applications.

Walking the Thin Line
Thin-wall applications are often used to reduce weight without sacrificing structural integrity. Parts like fuselage skins, wing sections and other structural components rely on this technique. However, machining thin walls can be challenging due to vibration, deformation, and heat. To address these challenges, adjusting the feed rate and depth of cut can help reduce vibration before resorting to complex setups.
Dampening tools at lower spindle speeds can improve stability without compromising finish quality. Kennametal’s high-feed mills and coated carbide inserts can successfully machine titanium for fuselage sections, maintaining wall stability and accuracy.
In relation to spar fittings, machining composite components and aluminium, which consist of thin walls, requires careful part movement and precise and rigid fixturing while managing machining around multiple pockets.

Milling Applications
Machining materials like titanium, Inconel, and CFRP can present obstacles due to their strength, lightweight, and resistance to high temperatures. Superalloys and hardened metals generate significant cutting forces, leading to vibration, deflection, and tool wear, especially when tight tolerances are required. Aerospace components are often complex and have 3D shapes, requiring multi-axis milling and customised tooling strategies to ensure accuracy in hard-to-reach areas.
“Our advanced milling solutions are specifically designed to address unique challenges, providing efficiency and accuracy when machining high-performance materials like titanium and Inconel,” said Patrick Mesnil, District Business Manager and aerospace business leader France & Benelux.
Advanced tooling coated with Diamond-Like Carbon (DLC) or PCD can improve cutting efficiency. Optimised cutting conditions, including adjusting speeds, feeds, and depths of cut, help manage heat and forces during machining. Effective cooling solutions, like high-pressure coolant, dissipate heat and prevent workpiece deformation. Multi-axis CNC machines allow for precise machining of complex 3D shapes, ensuring accuracy in hard-to-reach areas.

Surface Finish
When it comes to high-temp machining, achieving quality surface finishes is essential. It can be affected by factors such as tool wear, cutting speed, feed rate and the material being machined. Advanced multilayer coating technologies like TiAlN and AlTiN on their carbide tools help control the heat at the cutting edge. These coatings act as a barrier, reducing friction and heat transfer.
As new aircraft standards emerge, emphasising lighter, more heat-resistant, and sustainable components, continuous innovation in tool geometries and coatings plays a critical role in advancing component development.

For example, larger components, such as engine cases, require challenging process controls and careful application with tool pressure in mind. Internal and external milling operations must also consider thin walls and fine surface finish requirements when working with tough materials.
Additionally, turbine disks require managing low thermal conductivity and vibration to avoid part deformation. This requires application-specific tooling to provide the required cooling capabilities and productivity.
As the industry continues to explore new materials and complex geometries, advanced tooling solutions must meet emerging challenges. In high-temperature machining, where precision, reliability and speed are crucial, Kennametal’s tools provide aerospace manufacturers with solutions to support the next generation of high-flying components. Designing and engineering tools that solve today’s challenges and anticipate tomorrow is essential.