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Index Page

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Dear colleagues, These are exciting times for Aerospace

Manufacturing Industry. The recent International Air Transport Association (IATA) announcement of Asia Pacific edging past North America and Europe to become the

world's largest aviation market has reaffirmed Asia's leadership prospects in the

global aviation arena.

The succesful test flight of the the Boeing dreamliner has given a fillip

to the industry throughout the Asia Pacific region,resulting in a ramp up of

production at all the facilities.

We were never better placed to face this challenge.With a strong Aerospace

Frame package ,including the new grades for Titanium machining in CP 10.1 along

with the advanced application training for our engineers in China,Japan,South East

Asia and Australia-we have the best package available in the market today.

Production forecasts-Number of Boeing 787 planes per month.

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This very much includes the successful partnership with Precorp US for

offering solutions in Carbon Fibre Reinforced Plastics.(Upto 50% of the wide body

plane is made of light composite materials).To cite one example,the tool life for

drilling in a composite material was improved for 5 pieces per drill to 25 pieces!!

You shall find more details inside this first qtr newsletter .

In the end, please find enclosed the picture of the Boeing Dreamlifter spotted

recently at Nagoya airport. This one-of-its-kind cargo plane was specially designed

for transporting the dreamliner aircraft parts to Boeing from suppliers around the

world.Coming soon to an airport near you!!

Happy reading and let’s all keep the Aero focus flying high!!

Best regards

Pulkit Datta

Regional Aerospace Driver-APAC

www.aero-knowledge.com

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Titanium Machining Training in Shanghai

Totally15 Aerospace specialists from Sandvik Coromant China as well as SSEA participated in the Titanium Machining Training in Shanghai.

The training were based on the Aerospace TTT

course that took place in Sweden last year and the

purpose was to build application knowledge and

confidence especially in the new Ti grades S30T

and S40T.

Totally15 Aerospace specialists from Sandvik

Coromant China as well as SSEA participated in the

3 day course.

The training focused on practical machining of Edwin Guo holding the deep pocket Demos

component features in Ti6Al4V and

Ti5553-typical materials within the

Aerospace frame segment and

covered all aspects of the new

Titanium Application DVD. The

machine demonstrations that were

carried out included machining of

Corners in 2D pockets, Thin wall,

Some of the components machined in Ti64 and Ti5553

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Thin base, Large holes, Heel

machining etc.

AAT –Titanium Frame Machining-Australia The 1st Ti AAT session was held in Dandenong on the 10th and 11th March. Attending were 5 employees with varying roles.3 were senior sales engineers with key Ti / aerospace accounts, the other two were senior sales engineers . The demos were based around the 2D pocket on the DMU 80-C5 machin and ran over . two days. Day 1 was used to cover all the theory behind Ti machining including discussing the material, modern milling techniques, what the customer expects from us. It was interesting to see the guys take on board the challenges faced with Ti machining, but in the same note, realise that Ti is just another material to machine. Not to be overwhelmed by it. Day 2, practical work. Each of the 2 groups was given a copy of the model drawing, dimensional drawing, tool list & programs available. In their groups they came up with tooling, methods & data for each operation. After a predetermined amount of time, all got back together to share the findings. Then as a group ,a method was selected & run on the machine.

Overall the guys gained more confidence in their ability to handle technical assistance at customers that are venturing into Ti machining.

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Advanced Ti Frame Application Training in Nagoya, Japan

15 Aerospace specialists from Sandvik Coromant Japan participated in the Titanium Machining Training in Nagoya.

During week 10, a 2-day training course in Titanium Frame machining was

organised for the Japanese sales team in Nagoya, Japan.

The purpose of the course was to improve the

application know-how within the Aerospace

organization and build confidence - especially in

the new Ti grades-S30T and S40T. The training

focused on practical machining of component

features in Ti6Al4V within the Aerospace frame

segment.

A total of 15 participants took part in the 2-day

course. The machine demonstrations included

machining of corners in 2D pockets, thin- Participants in group discussions before running each demo on the machine walled- and thin-based components, large holes, heel machining etc.

With new aircraft programs such as the Boeing 787 (Dreamliner) and the

indigenously developed Mitsubishi Regional Jet, all indications point to continued

growth of Aerospace potential in Japan.

"This training will go a long way in bringing us closer to the obective of being number

one in the Aerospace Frame segment in Japan’’ said Toshikazau Kawamukai, Sandvik

Coromant Japan’s Aerospace SDC manager.

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Composites Strategy Meeting-Asia All indications point towards a increase in the Composites Machining potential in Asia-the main drivers being the Boeing 787 Dreamliner and the Airbus 350 programs along with the indigenously developed regional jet in Japan-MRJ. The 787 production would increase 5 folds in the coming 3 years. (From existing 2 planes to 10 per month)

Participants from Sandvik Coromant and Precorp US in the meeting in Nagoya In order to gear up to this big potential ,utilise the global partnership with Precorp US on a regional basis and prepare the action plans,a series of strategy meetings were held in week 10 and 11 in China and Japan respectively,which included a formal introduction/briefing of the partnership between Sandvik Coromant and Precorp US

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Following are the highlights:

• The machining center in the Shanghai AC would be retrofitted with dust extraction system, enabling the tests to be carried out on Composite materials both for internal competence development and specific customer projects. The investment in the PC in Nagoya is also being considered

Proposed retrofitting for the machining center at Shanghai and Nagoya PC

• China and Japan would consider investing in hand held power feeder equipment for drilling. Talks being organized with Cooper Tools in both the countries. Power feeder

• Dedicated resource for Composite

business development in Japan and China. The person shall be developed for handling the composite applications, including the onsite training and orientation in Precorp plant in US.

• Regrinding for the composite tools: Given the potential and the sheer number of tools involved in a typical project-it is important that a local regrinding should be established in Asia. The preference of location would be Japan, with proximity to the big accounts. Francis Richt shall drive the discussions further with Sandvik Tooling about the investment.In the meantime-Precorp shall be the facility for regrinding

• Specific customer projects in China and Japan have been identified and action plan prepared with clear local,ABC and Precorp responsibilties.A monthly telephonic review meeting has also been decided for the projects in Japan.

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Atsushi Takei/Nagoya Branch Japan

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Market :China

� Operation: high feed milling for open pocket

� Materials: TC18(characteristic close to β titanium), HB350

� Background: The customer use our 1030 and 2040 for titanium milling.

S40T was tested to strengthen our business

� Component analysis: It's a half open pocket machining, but the corner

radius is almost equal to cutter diameter. It’s a tough and dangerous for high

feed milling, also no feed optimizing at the corner.

� Tool assembly:

– C5-391.05-22 025 + C6-391.02 50 080A +C6-390.58-50040 + R210-

063Q22-14M

� Inserts tested

– R210-140514E-PM CAA(S40T)

– R210-140514E-PM 1030

– R210-140514E-MM 2040

� Cutting data

– Vc=39.5m/min, fz=0.68mm/z, ap=1.5mm, ae=40mm, n=200rpm,

vf=550mm/min

� Results: CAA(S40T) performed better in tough condition than old

1030 and 2040

CAA(S40T)— 60min/edge, smooth and even flank wear

1030— 30min/edge, non- controllable tool life, risk of edge breaking

2040— 45min/edge, the wear pattern of main cutting edge similar with

S40T, but more serious wear on insert corner

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Underwing Box Vinayak Bhat –PIE

Market and zone India,Bangalore Application: Engine, Frame or L-Gear

Landing Gear

Customer Quest Machining & Manufacturing Pvt. Ltd. Component name Underwing Box (Ti Box) Material Ti6Al4V (forged & annealed) Product CM390-18 mm Long edge cutter Dia.54 Application Rough Milling-External & Pocket Milling. Competitor Competitors like Mitsubishi,Kenna were constantly

attacking our existing R390-H-PL 1030 solution because of customer concern of higher tool cost/component.

Cutting parameters Vc=42m/min, Fz=0.1mm/r, Vf=75mm/min, ap=30 mm,ae=15 mm

Coromant solution Cutter R390-054C5-43M,Insert R390-18 06 12 H-PL S30T

New cutting parameters Vc=42m/min, Fz=0.1mm/r, Vf=75mm/min, ap=30 mm,ae=15 mm

Overall result

Tool life improvement by more than 50%. Overall Tool cost reduction by 30%. Cutting with S30T was smoother & with less noise level. We observed more than 50% improvement in tool life.Delighted with success of S30T, customer has

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decided to put S30T in all other Coromill applications & he has also asked Vinayak to try S30T in other applications where competitor cutters are running.

Customer: Weston Sea Ltd-Thailand Aerospace stator Operation : Slot milling Component : Aerospace Stator Material : Inconel 718, CMC20.22, 45HRC Objective : Reduce tooling cost with higher productivity Current insert Proposed solution R390-11T320E-PM 1030 R390-11T320E-PM S30T Straight in tool path Roll in tool path Vc 20 m/min Vc 25 m/min fz 0.03 mm/z fz 0.04 mm/z ap 2 mm ap 2 mm ae full slot ae full slot Cycle time 5 min 5 sec Cycle time 3 min 43 sec Tool life 20 pcs Tool life 30 pcs

Pitsanu Srichangsan-PIE Thailand

Slot machining

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Material :Stainless Steel 316 Operation: Helical Interpolation

Yan Ling Goh-PIE Malaysia

Current Solution Proposed Solution Walter high Feed R210-063Q27-14M Insert P263335R14 WSM 35 R210-140514E-PM S40T Vc 204 m/min Vc 158 m/min fz 0.7 mm fz 1.07 mm ap 0.8 mm ap 1 mm ae 70% ae 70% depth reached: 6.4mm depth reached: 33.6mm tool life 15 min tool life 66.57 min

Productivity increase by 91%.!! 4 times better tool life!!

WSM 35 S40T

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Mikizou Matsui/Omiya Branch-Japan

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Application Frame Component Name Carrier Material SS 4330, 33HRC Competitor Data Flute(Solid Carbide) Cutting Parameters Vc=80m/min Vf=100mm/min, ap=4mm, ae=3mm Coromant Solution 316-12SM440-12004K 1030 Coromant Cutting Parameters

Vc=90m/min, Vf=400mm/min, ap=4mm, ae=12mm

Customer Value 74% Productivity Increase Savings in Production time is 125 hours

Success Factors Increased Tool life from 5 pcs to 10pcs Cycle time reduced from 16min to 11min Improved process

Eugene Peralta-PIE Philippines

Customer: MOOG CONTROLS CORP

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Mikizou Matsui/Omiya Branch-Japan

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Case 1

Part name ; Inner Shroud Material ; 6-4 Ti-Alloy Machine ; MM58 (Din 69871 Taper 50) Existing Process Turn + Mill Proposed Solution Turn Milling Cutter 316-12SM450-12030P 1030 Parameters Vc150m/min,F 960mm/min,Ap 0.2 and Ae 10mm Results Productivity Improvement :300% Time Saved/Component :10 hours

Jaehun Lim-Aero specialist Korea

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Case 2

Part name ; Engine Ring Material Inconel 718 Application Slot Machining Existing Process Hitachi Solid Carbide Endmill Vc=15m/min, Vf=40mm/min Proposed Solution Coromill 316 Cutter 316-12SM450-12030P 1030

Vc40m/min, Vf=170mm/min, ap=6mm, ae=5mm Results One single pc 316 head for roughing and finishing Time Saved/Component :2.5 hours

Cutting edge after 1

component

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Case 3

Part name ; Engine Pad Material Inconel 718 Application Profile Machining Existing Process Local made Solid Carbide Endmill Proposed Solution Coromill 316 Cutter 316-10BM440-10050G 1030

Vc100m/min, Vf=1000mm/min, ap=1 to 4.5mm mm, ae=0.8mm

Results 3 components per single pc 316 head Time Saved/Component :2 hours

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Japan

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GC1115 on Hastelloy Alloy

Application:OD Turning Existing solution:Iscar IC907

WNMG 080412-NR Existing paramters Vc 40m/min,f 0.2 mm/rev ,Ap 0.6mm

Tool life 4 pieces per edge Coromant Solution

WNMG 080408-QM 1115 Vc 60m/min,f 0.2 mm/rev , Ap 1.1mm

Tool life 13 pieces per edge

Jack Xiang-China

120 mm

Ø 28.7 mm

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OTS order for 13 machines

tool up at UPECA Aerotech

Malaysia

In a major breakthrough ,the team in Coromant South East Asia has been successful

in receiving an OTS order to tool up 12 new machines ,as part of expansion at

Upeca Aerotech

The customer ,based at Kuala Lumpur landed a RM270m(0.6BSEK) Spirit contract to

supply Airbus 320 aero-structural parts last year .

‘’The central support and OTS responsible were involved right from the start ,in

providing a preliminary technical proposal to over 100 different components ,winning

the trust and confidence in customer’s mind to be their productivity partners.’’says

Raymond Tan ,PIE for Upeca Aero.

The initial order for the First Articles(FAs) is worth MYR 200K and the regular

production is slated to start in Jan 2011.The tooling management software AutoTas

shall soon be implemented soon as well.

Raymond Tan-PIE Kuala Lumpur