The JP Performance titanium rim is a globally unique project. A rim made of Grade 5 titanium – a material otherwise used in aerospace – was manufactured for the legendary Jaguar E-Type. It took over 160 hours of machining time to transform the 400 kg raw block into the finished 18 kg rim. The project began through a collaboration between Ladermanufaktur GmbH and JP Performance. We were directly involved as a tooling partner and played a decisive role in the manufacturing process with our high-performance titanium milling cutters.

Material & starting point: Grade 5 titanium

The journey to creating JP Performance titanium rims begins with a solid 400 kg block of titanium. Grade 5 titanium impresses with its high strength, corrosion resistance, and low thermal conductivity. These material properties make machining particularly challenging. Without the milling cutters specially developed for titanium, the transformation from raw block to high-end rim would not have been possible. Our tools ensured maximum stability, process reliability, and precision.

Manufacturing & machining: 160 hours of high-end machining

The production of the titanium rim is a prime example of high-end machining. Creating each rim from a 400 kg block of titanium requires over 160 hours of machining time. The process uses the following:

• 5-axis milling, including simultaneous machining
• CAM software: SolidCAM with strategies such as iMachining 2D/3D
• Machining methods: High-speed machining

Developed for extreme conditions, our titanium milling cutters ensure precision when machining complex geometries. Tool lengths of up to 400 mm placed special demands on stability and vibration damping.

Design & aesthetics of the titanium rim

The rim design is turbine-like, with deeply machined spokes and clearly defined contours. It combines the classic elegance of the Jaguar E-Type with state-of-the-art high-end manufacturing. Tailoring each contour to the capabilities of the tools and the machining strategy ensures precision. The result is technical perfection and aesthetics in a unique piece.

Technical challenges in titanium machining

Experts consider titanium a particularly challenging material for machining. The deep pockets and long milling cutters (up to 400 mm) create vibration risks and stability problems. The high strength and low thermal conductivity increase the risk of tool breakage and material overheating. In addition, the enormous material removal from the 400 kg raw block to the final weight of 18 kg must be precisely controlled.

Our solution consisted of optimized tool paths, adaptive cutting parameters, and continuous process monitoring. Every decision was based on our direct expertise in the manufacturing process.

Source: DMG MORI / YouTube, Video „JP Performance x DMG MORI Teaser: Machining a Complete Titanium Rim“, https://www.youtube.com/watch?v=vRAN-JgLzEs

Project facts at a glance

• Material: 400 kg titanium grade 5
• Processing time: >160 hours per rim
• Machine: DMG MORI DMU 85 H monoBLOCK
• Dimensions: Ø 560 mm x 371 mm
• Partners: HAM Präzision, DMG MORI, SolidCAM, Ladermanufaktur GmbH, AVANTEC Zerspantechnik, Rosswag Engineering

Conclusion: High-end rim from JP Performance

The titanium rim from JP Performance is a unique piece that is one of a kind worldwide. Our tools and expertise were crucial to its implementation. The project combines high-end machining, material expertise, and design at the highest level.

Der Beitrag JP Performance titanium rim: From a 400 kg titanium block to a high-end rim – our tools in action erschien zuerst auf HAM Präzision.

Aluminum is omnipresent. We encounter it in vehicle bodies, aircraft structures, machine components, packaging and in many industrial applications. The reasons for this are obvious: the material is light, malleable, corrosion-resistant and impresses with its excellent conductivity. However, it is precisely this diversity that poses particular challenges for manufacturers. This is because aluminum machining is anything but a matter of course.

Depending on the alloy, strength and structure, it reacts very differently to machining processes. Chip sticking, built-up edge formation and abrupt tool wear are just some of the typical side effects. The challenges often lie in the details and the path to a stable, efficient process is rarely straightforward. What makes the decisive difference only becomes apparent when you delve deeper.

From lightweight to high-performance: What makes aluminum so attractive for machining

As a material, aluminum has an exceptional combination of technical properties that make it particularly attractive for machining. Aluminum naturally forms an oxide layer that protects it from corrosion, and anodizing can further enhance this protection — a clear benefit in harsh environments or for demanding surface requirements. At the same time, aluminum conducts heat and electricity very efficiently: with around 60 percent of the thermal conductivity of copper and an electrical conductivity of around 62 percent at only a third of the weight, it is ideal for lightweight, high-performance components.

The material also offers advantages both visually and functionally. It reflects up to 90 percent of thermal radiation and 80 percent of light, making it predestined for use against light and thermal radiation in applications such as roofing and heat shields for motor vehicles. In terms of sustainability, it scores highly with its excellent recyclability. Recycling uses only a fraction of the energy while maintaining full quality and strength. Furthermore, it generally does not require any additional protective coating, as simple processes such as brushing or shot blasting are usually sufficient. However, if increased protection is required, additional surface treatments such as paints or electrochemical treatments (e.g. anodizing) can be applied.

Light, strong, versatile – ideal conditions for machining

A decisive factor for aluminum machining is the excellent ratio of weight to strength. This makes the material ideal for lightweight, robust constructions, such as in vehicles or aircraft. It also impresses with its uncomplicated processing: it can be produced in almost any desired thickness. Its easy machinability – for example through turning, milling, or grinding – and the high processing speed also make production more economical. Furthermore, it is highly formable and can be processed into fine threads or complex shapes without breakage. Despite its lower ductility compared to copper, its low density and low melting point enable the flexible production of a wide range of products such as sheets, tubes or rods..

Aluminum also shows its strengths at low temperatures: it does not become brittle, but stronger, and remains corrosion-resistant. It is also non-magnetic, which makes it ideal for shielding antennas and computer panels. Anyone who wants to machine aluminum is working with a material that is not only light and conductive, but also robust, sustainable and extremely versatile. Provided you know its characteristics and use the right precision tools, such as those developed by HAM.

Not all aluminum is the same, and that makes all the difference

Aluminum is a real lightweight with amazing strength. Compared to other materials, aluminum is in the middle range in terms of strength. However, when its density is taken into account, it clearly stands out and even surpasses steel. It is precisely this ratio that makes it so attractive for lightweight construction. Aluminum has played a key role in automotive engineering, aviation, and mechanical engineering for many years.

But as versatile as the material is, it also behaves differently when it comes to machining. Because not all aluminum is the same. In addition to pure aluminum, there are a variety of aluminum alloys with their very own properties. While pure aluminum is very soft and only has low strength, alloys usually have significantly better prerequisites for aluminum machining. A distinction is made between wrought alloys and cast alloys. Both types are basically machinable but require a differentiated approach.

In practice, aluminum alloys are divided into three classes. Class one comprises very soft materials with low strength. These often produce greasy chips during machining, which stick to the tool and lead to the formation of built-up edges. Class two describes materials with increased strength in the range of around 300 to 600 Newtons per square millimeter. These alloys are significantly more stable and lead to fewer built-up edges. Class three stands for free-cutting materials and wrought materials with chip-breaking additives such as lead. These additives ensure clean chip formation and significantly reduce the tendency for built-up edge.

The biggest challenges in machining aluminum

At first glance, aluminum seems like a dream partner for machining. Light, easy to shape and clean to process. But when you stand at the machine, you quickly realize that this material also has its peculiarities. In particular, the sticking of chips and the stubborn built-up edge make even experienced machining professionals break out in a sweat. Especially when milling aluminum, these effects can have a negative impact on dimensional accuracy, tool life and surface quality.

One key to successful aluminum machining lies in high-speed machining. Combined with a carefully selected cooling lubricant strategy, many problems can be avoided from the outset. Aluminum generates significantly lower cutting forces than steel during milling, often only about a third. This property allows high cutting speeds, but at the same time requires consistent control of the chip flow.

To ensure process stability, it’s crucial to remove chips from the cutting zone quickly and efficiently. This requires special tools for aluminum with smooth, slippery surfaces that prevent sticking and actively remove the chips. Milling cutters with a lower number of teeth than tools for steel are also characteristic. This design significantly improves the chip flow. Coordinated coating solutions, when integrated into the process, reliably control even sticky aluminum chips.

These are the factors that really matter when machining aluminum

If you want to machine aluminum reliably and precisely, you have to master the interaction of many components. It starts with the machine itself. It should not only work stably, but above all be prepared for the use of modern cooling lubricant solutions. Systems like the AerosolMaster 4000 ATS from Blum-Novotest enable highly efficient minimum quantity lubrication by precisely dosing a fine film of lubricant. At the same time, the machine must support internal and external cooling options and allow clean adaptation to dry machining, emulsion or MQL.

Another cornerstone of aluminum machining is the clamping. The tool holder and workpiece holder must grip precisely to avoid vibrations and ensure clean chip formation. In MQL machining, the cooling channel must be optimally positioned to ensure effective performance. This is the only way to ensure reliable chip removal without leaving any residue in the machining zone. When drilling, for example, a special clamping structure with a central lubricant supply via the holder can be crucial.

And let’s not forget the digital side of the process. CAM programming has a massive impact on efficiency and tool life. Those who rely on well thought-out strategies and smart adjustments to the cutting values not only save time but also ensure uniform surfaces. Those who rely on well-thought-out strategies and smart adjustments to cutting parameters not only save time but also ensure consistent surfaces. Technology such as SolidCAM‘s iMachining, in combination with optimized cutting data, enables a constant load and reduces thermal peaks at the same time.

However, the optimum machine, perfect clamping and intelligent programming only unfold their full potential in combination with the right tool. This is because the cutting material, cutting values, tool geometry and surface technology determine the cutting quality and process stability, especially with aluminum. Therefore, it’s worth taking a closer look at the specific requirements of tools for aluminum machining.

What makes our tools so special when machining aluminum

What truly makes a tool for aluminum machining outstanding isn’t just the cutting material used or a single design feature. It’s the interplay of sophisticated materials, sophisticated geometry, and state-of-the-art surface technology that makes the decisive difference.

When it comes to cutting materials, we specifically focus on two proven materials: polycrystalline diamond (PCD) and solid carbide. PCD tools are the first choice for machining abrasive aluminum alloys with a high silicon content or for very high-volume production combined with long tool life. They are characterized by exceptional wear resistance and deliver consistently high surface qualities – an advantage that is particularly in demand in sensitive sectors such as aviation or automotive engineering.

Solid carbide tools, on the other hand, score points for their versatility. They are ideal for smaller series or for processes that require a high degree of flexibility. Their advantage lies not only in their good cutting performance, but also in the fact that they are generally more cost-effective than PCD tools. They are also a particularly good choice when machining other materials in addition to aluminum, as they are suitable for a wider range of applications.

Geometry and surface technology as the key to performance

The tool geometry is decisive for the quality of machining. Our milling cutters have precisely ground cutting edges, a sharp point and defined cutting edge rounding. Internal cooling channels enable an efficient supply of cooling lubricant, while flat helix angles and uneven helix pitches minimize vibrations and improve chip breaking at the same time. The chip chambers have also been specially designed for aluminum alloys to ensure reliable chip evacuation. The strength of our tools is particularly evident when drilling: The specifically designed MQL chamfer on the cutting edges optimally supports aerosol lubrication and makes the tools particularly efficient in combination with modern MQL systems.

A decisive contribution to tool performance comes from surface technology. In order to meet the high demands placed on PCD and solid carbide tools, HAM has developed Hybrid Surface Finish, or HSF for short, a hybrid and technologically highly complex solution. This produces a defined surface finish while simultaneously homogenizing the cutting edge. In combination with a precisely coordinated grinding quality, this creates a high-performance overall system.

For tools with shank diameters up to 32 millimeters, we apply PVD hard coatings such as TiN, TiAlN, TiNAlOx, or AlOx. The HSF process ensures mirror-smooth surfaces on carbide and PCD, for diameters between 0.5 and 32 millimetres. Depending on the application, defined cutting edge preparations of 4 to 20 µm are achieved. The tool’s meticulous design comes to life only when all its properties are combined optimally, unleashing its full potential.

Machining aluminum – exploiting potential, mastering challenges

Machining aluminum is more than just a routine production step. Different alloys, complex material properties and process-specific requirements demand a high level of expertise. If you want to manufacture economically and reproducibly, you need to have the entire machining process under control – from material selection and the optimum cooling strategy to the precise coordination of machine, clamping and CAM programming. The high quality that modern applications require today can only be achieved if all factors are interlinked.

With our many years of experience in aluminum machining and our highly developed tool solutions – from polycrystalline diamond to finely tuned solid carbide – we not only offer individual components, but also sophisticated overall solutions. Technologically leading geometries, specially developed surface treatments such as HSF and perfectly coordinated coating concepts make our tools the first choice for demanding production tasks. Anyone who wants to machine aluminum efficiently and reliably benefits from our expertise down to the smallest detail.

Practical application

In our workshop “Zerspanung ALU – Best of HAMmer”, we showed how theory and practice can be optimally combined. We machined a component made from the high-strength aluminum alloy EN AW-2017A. This alloy is an age-hardenable material that develops its full strength potential after targeted heat treatment, such as solution annealing with subsequent cold ageing. It plays a key role in the aerospace and defense industry in particular due to its high mechanical strength and good machinability.

The workpiece, measuring 200 x 100 x 25 millimetres, was machined on a Hermle C12U, controlled by a Heidenhain TNC 640. We used a zero-point clamping system from LANG to ensure reliable and repeatable clamping. In combination with a precise tool holder from Diebold based on HSK-A63, a high level of stability was guaranteed.Milling was performed with targeted use of minimum quantity lubrication and classic cooling lubricant, ensuring optimal chip removal and maximizing tool life based on the machining area.

When everything works together, it shows how powerful aluminum can be in the right environment.

Der Beitrag How to achieve perfect aluminum machining: Aluminum machining live in the workshop! erschien zuerst auf HAM Präzision.

They are the exotics among the materials: Materials such as CFRP, titanium, honeycomb or aluminium are convincing due to their high strength combined with low weight and are preferably used in the aerospace industry. However, they place high demands on machining. HAM has been dealing with this topic for years and has developed a multitude of powerful standard and special tools. They score with long tool life and achieve very good surface finishes…

Leistungsstarke Präzisionswerkzeuge von HAM für CFK, Titan & Co.

Während CFK oder Titan in der Luft- und Raumfahrt schon seit längerem im Einsatz sind, setzen sich solche modernen Werkstoffe in der Automobilindustrie erst allmählich durch. Bei den Konstrukteuren sind die Materialien allemal sehr beliebt: Sie sind leicht und dennoch fest und stabil. Faserverbundwerkstoffe wie CFK bestehen beispielsweise aus einem Matrixwerkstoff und verstärkenden Fasern. Diese Kombination macht das Material hochfest. Aluminium wird bevorzugt dort verbaut, wo es auf die Masse ankommt, wie etwa bei Flugzeugen. Denn durch die geringe Dichte wird erheblich an Gewicht gespart. Die wabenförmige Struktur von Honeycomb besteht aus Kunststoffen oder Aramidfasern, die mit verschiedenen Decklagen überzogen werden. Dies erhöht die Stabilität deutlich. Titan und seine Legierungen zeichnen sich durch eine geringe Dichte und hohe Festigkeit aus. Die Werkstoffe sind thermisch stark belastbar und korrosionsbeständig.

Zerspaner vor großer Herausforderung

Allen gemeinsam ist, dass sie die Zerspaner vor große Herausforderungen stellen. Die spezifischen Eigenschaften dieser Werkstoffe machen eine prozesssichere und schnelle Bearbeitung mit hohen Oberflächenqualitäten sehr schwierig. So ist beispielsweise CFK stark abrasiv, was zu einem deutlichen Werkzeugverschleiß führt. Insbesondere bei Material mit viel Harzgehalt kommt es bei der Zerspanung immer wieder zu Absplitterungen. Die Inhomogenität von CFK und anderen Verbundwerkstoffen belastet die Werkzeugschneide erheblich. Das Material zerspant staubförmig. Ein zu hoher Wärmeeintrag kann zu unerwünschten Verschmelzungen führen. Für eine prozesssichere Bearbeitung sind die Auswahl des richtigen Werkzeugs, die passende Geometrie und die Bestimmung der geeigneten Schnittdaten entscheidend.

Das leichte und dennoch biegefeste Honeycomb wird gerne zwischen der Innen- und Außenhaut von Flugzeugen oder in den Flügeln von Windkraftanlagen zum Stützen und Versteifen eingesetzt. Das Material besteht jedoch aus einem vergleichsweise losen Verbund, wodurch es beim Bearbeiten leicht ausfransen kann. Gefordert sind hier extrem scharfe Schneiden. Die Schwierigkeit beim Bohren und Fräsen besteht darin, neben einer kontur- und maßgetreuen Bearbeitung auch hochwertige Schnittkanten und Oberflächen sicherzustellen.

Große Hitzeentwicklung bei Titan

Beim Zerspanen von Titan und seinen Legierungen entsteht große Hitze. Diese nimmt nicht der Werkstoff auf, sondern das Schneidwerkzeug. Es muss daher die richtige Geometrie und Beschichtung gewählt werden, um frühzeitige Ausfälle zu vermeiden. Außerdem bilden sich beim Fräsen und Bohren von Titan oft lange Späne, die sich um Werkstück oder Werkzeug wickeln und den Prozess unterbrechen können. Am vergleichsweise unproblematischsten ist das Zerspanen von Aluminium, das unter hohen Schnittgeschwindigkeiten erfolgen kann. Die Spanbarkeit ist jedoch abhängig von den Legierungsbestandteilen. Kaltverfestigtes oder gehärtetes Aluminium lässt sich leichter bearbeiten als weiches. HAM beschäftigt sich seit Jahren intensiv mit der Bearbeitung moderner Werkstoffe und hat Werkzeuge entwickelt, die die Herausforderung dieser Exoten meistern. So überzeugt beispielsweise der zweischneidige VHM-Spezial-Konturenfräser von HAM bei der Herstellung von Nuten verschiedener Tiefen aus Honeycomb-Platten mit beidseitiger Deckschicht. Bei einer Schnittgeschwindigkeit von 376 Metern pro Minute und 20.000 Umdrehungen erzielte er eine nahezu gratfreie Oberfläche. Ausfransungen an den Folien blieben aus. Mit einem erreichten Standweg von 450 Metern bei Langzeitversuchen hat der Fräser seine Prozessfähigkeit für die Serienfertigung unter Beweis gestellt.

HAM-Bohrsenker für Top-Oberflächenqualität

Eine häufige Anwendung in CFK ist das Bohren und Senken von Nietlöchern in einem Arbeitsgang. Die besondere Aufgabe besteht darin, Ausfransungen am Bohrungsein- und – austritt zu vermeiden. Hierfür hat HAM einen Vollhartmetall (VHM)-Bohrsenker entwickelt. Mit seiner speziellen Geometrie und angepasster Diamantbeschichtung erfüllt er die Anforderungen an Bauteilqualität und Standzeit. Das Werkzeug erzielt maßgenaue Bohrungsdurchmesser und Senkungen. Zwischen den Materialschichten gibt es keine Ausfransung und die Oberflächenqualität ist sehr gut. Hohe Vorschübe und Schnittgeschwindigkeiten beim Fräsen von CFK ermöglicht beispielsweise der PKD-HPCAufsteckfräser HAM 40-7640. Das polykristalline Diamantwerkzeug sorgt in der Praxis für eine hohe Abtragsleistung. Die effiziente Kühlung erfolgt innen zentral durch die Anzugsschraube.

Mit dem One-Shot-Drill hat HAM ein leistungsstarkes Werkzeug entwickelt, das Bohren und Reiben von Sandwich-Bauteilen, aber auch von Titan in einem Arbeitsgang ermöglicht. Das Werkzeug mit Diamantbeschichtung erleichtert die Bearbeitung von Titan. Der Bohrer erzielte in Tests mit einer Schnittgeschwindigkeit von 25 Metern pro Minute einen präzisen Durchmesser und hohe Oberflächengüte. Die Minimalmengenschmierung vermeidet eine zu starke Hitzeentwicklung an der Schnittzone von Titan-Bauteilen. Darüber hinaus erzeugt das Werkzeug kurze Späne, die leicht zu entsorgen sind. Der One-Shot-Drill überzeugt auch bei Sandwich-Bauteilen aus CFK, Titan und Aluminium. Er vermeidet Ausfransungen in der CFK-Schicht, und der Bohrungsaustritt ist nahezu gratfrei.

Die Verwendung moderner Werkstoffe wird in Zukunft weiter zunehmen. Zu verlockend sind die konstruktiven Vorteile, die diese Exoten bieten. Die Hersteller von Präzisionswerkzeugen bleiben gefordert. HAM wird sich auch weiterhin in enger Kooperation mit den Kunden intensiv mit diesem Thema auseinandersetzen und geeignete Werkzeuge für die effiziente und wirtschaftliche Bearbeitung von CFK, Titan & Co. entwickeln.

Der Beitrag A firm grip on the exotic erschien zuerst auf HAM Präzision.