Fullerton has become an authorised manufacturer and distributor of 5ME’s BlueZone cryogenic tooling, particularly carbide end mills and drills designed for use with 5ME’s cryogenic machining systems. Star SU is authorised to manufacture and market 5ME’s BlueZone cryogenic tooling designs for end mills, ball mills, tapered ball mills, thread mills, reamers, and drills. Both agreements are only said to cover sales and service in North America.
5ME’s cryogenic machining process enables higher cutting speeds for increased material removal rates and longer tool life by transmitting liquid nitrogen at -196° C through the spindle/turret and tool body, directly to the cutting tool’s edge. According to Fullerton, applications for cryogenic machining include high-speed cutting of titanium and other tough-to-cut alloys common in aerospace, heavy equipment and energy part processing. Fullerton provides custom carbide tools thanks to a dedicated R&D lab.
Bill Horwarth, president of 5ME, says: “We’ll work closely with the Fullerton team to develop the next advanced-performance BlueZone tooling, as well as testing on materials to optimise coatings, cutting geometries, and machining parameters.”
The announcement came days after other news that 5ME had acquired 51 patents from cryogenic systems company Creare.
In 2003, Creare, along with the U.S. Navy, Navair, and Bell Helicopter, led the R&D for cryogenic machining and tooling in test environments through a Small Business Innovation Research project. 5ME then evolved the technology through trials at its technology centre in Warren, Michigan, and eventually arranged beta tests in practical applications with aerospace OEMs, heavy equipment manufacturers and others.
Adds Horwarth: “We applied what we learned working with Creare in controlled environments and gave it ‘real-world’ exposure in the field, and the results were excellent. We’re seeing cryogenic machining gain wide acceptance, especially in aerospace and heavy equipment applications.”
He concludes: “The acquisition of this intellectual property puts all of the cryogenic machining technology and knowledge under one roof, allowing us to continue development of this revolutionary manufacturing technology as well as provide excellent customer service.”
In a recent case study involving a titanium aerostructure component, 5ME’s Cryogenic Machining Technology reduced the cycle time from 44 hours to 21 – an improvement of 52%. Other benefits included better surface integrity and part quality, reduced white layer, lower energy consumption, and improved worker health and safety through the elimination of traditional coolants.
