CNC machining of aerospace parts

At present, Boeing, Airbus and Bombardier occupy the main market share. China and Russia are preparing to enter the market as new competitors. my country's aerospace industry is constantly improving, especially the C919 research and development and succe

At present, Boeing, Airbus and Bombardier occupy the main market share. As new competitors, China and Russia are preparing to enter the market. my country's aerospace industry is constantly improving. In particular, the development and successful test flight of C919 greatly promoted local aviation. The development of aerospace parts manufacturing industry. As the machining difficulty of aerospace parts such as engine discs, shaft parts, turbine casings, landing gears, etc. continues to increase, various new materials, new structures, and new technologies are emerging in an endless stream, and the requirements for machining tools are also increasing. The pressure on component manufacturers of aerospace companies is increasing, and they must be as economical and efficient as possible in order to meet the challenges.

The cost of cutting tools largely depends on the requirements for parts, materials and processes. Reducing the wall thickness will cause the parts to become extremely unstable. The use of appropriate coolant also has a great impact on the service life of the tool. Therefore, the stability and clamping stability of the machine tool must be considered in the machining, and the cemented carbide matrix, The new coating technology and the macro geometry and micro geometry of the cutting tool play a very important role at this time.

This publication specially launches the introduction and examples of aerospace parts machining tools to provide users and enterprises with an information exchange platform. If users and readers encounter problems in machining, please leave a message for discussion.

Walter Xpress Aerospace Titanium Alloy machining Series

Titanium alloy is the most used material for aerospace parts. It is corrosion-resistant and high-temperature resistant. It is usually used for high-strength components, such as accessories around cabin doors and door frames, landing gear supports, underframe supports, or landing flap tracks. However, the chemical reactivity of this material is very strong, and it is very easy to cause the chips to be melted on the cutting edge during processing; because of the poor thermal conductivity of the material, the temperature at the cutting edge rises sharply, which leads to extremely bad chip conditions and abrasiveness. It is also extremely large; the smallest modulus of elasticity causes the workpiece to bend, and the material is solidified in the cutting edge area, so even a low cutting speed will shorten the service life of the tool cutting edge.

Walter Xpress aerospace products can meet the special requirements of the aviation industry. Walter Prototyp Ti38 Z6-10's powerful milling and innovative new coating can reach a cutting speed of 140m/min. The multi-tooth solution with up to 10 teeth can increase the feed rate by 50% when the contact width is small. Compared with traditional solutions, these solid carbide tool solutions can increase the metal removal rate by 50%.

HDC Ti38HPC Ti40Walter

An example of the newly developed substrate and coating technology is the PVD-based coating (physical vapor deposition) of the Walter Prototyp Ti series solid carbide. Compared with the traditional ANC coating (chromium aluminum nitride), this coating can extend the tool life by more than 100%. For example, when PrototypHPC Ti40 is used for semi-finishing and finishing of window frames made of 3.7164 titanium alloy with a tensile strength of 1250N/mm², the tool life is extended by 154%, that is, from the original 175min to 444min. The use of PrototypHDC Ti38 L for external finishing can extend the tool life by 116%, increase the speed by 25%, and increase the processing volume by 23%.

Another innovation is the CVD coating technology applied to the WSM45X tool material of indexable inserts, which can be used for Walter BLAXX M3255 corn milling cutters. The coating is equivalent to a thermal protection layer, which can make the cutting speed reach 65m/min, and the service life of the cutting edge of the tool can be extended to 130min, which doubles the service life of the tool of the titanium alloy structure. These machining processes are usually a combination of full slot milling and down milling, where the cutting speed is 45m/min and the feed is 0.12mm; another option is to increase the cutting speed to 65m/min, and the tool life remains constant, about 60min. The hardest known material PCD (polycrystalline diamond) cutting edge can also be used for fine milling.

BLAXX M3255 Porcupine Milling Cutter

Generally speaking, the concentration of cutting fluid and cooling medium has a significant impact on tool life. In this case, it is necessary to implement a corresponding cooling strategy to keep the cutting edge processing temperature at 600°C, and direct the cooling medium into the work area as much as possible, which can be achieved through the special coolant channel of the tool, and the current can reach 70bar high pressure cooling. Non-standard tool solutions for low-temperature processing use liquid carbon dioxide or liquid nitrogen processing, whichever is lower.

In order to meet customer needs, Walter provides tools, solutions and services for the entire process. Walter developed a "parts processing solution" many years ago, using CAM programs commonly used in the aerospace industry to develop non-standard processing strategies for all dimple shapes of structural parts. This "toolbox" enables the corresponding machining process to be quickly and efficiently derived from the 3D model of the customer's part. The delivery time of the Xpress tool solution is 2-3 weeks; the my.Walter software solution allows customers to cooperate with trained field service personnel to design tools online, and "WalterOnline Xpress" customers can receive the tool via email within 1h Binding quotation, including 2D drawings and 3D models.

Iscar launches cermet turning inserts with chip breakers

Iscar launched the ISO turning inserts of the cermet grade with a new type of chipbreaker specially designed for semi-finishing and finishing. All new blades are provided with IC20N and IC520N grades, which are mainly used for steel processing. Iscar offers a wide range of applications, double-sided and single-sided indexable cermet blades with different chipbreakers and geometries (including wiper blades). The chip breaker design is designed to ensure reliable chip breaking in fully automated processing applications. Iscar has launched a cermet turning insert with chip breaker covering several standard insert shapes, which helps to provide for each type of chip breaker. Select a more suitable chipbreaker for the specific application range.

Cermet is an ideal grade for super finishing, finishing and semi finishing of steel, powder metallurgy metals, difficult-to-machine cast iron and stainless steel materials. The use of cermet grades can often ensure a longer tool life when the chip load range is small to medium and the workpiece size consistency is high. The main advantage of cermet grades is that they are used in occasions with high demands on the processed surface quality, processing dimensional stability, and narrow tolerance bands. Compared with conventional cemented carbide grades, cermets can be processed at higher cutting speeds due to their higher hardness, better wear resistance, and can prevent the formation of built-up edge.

Zhengzuan PCD adjustable disc milling cutter

Zhengzuan Aviation's high-efficiency cutting tools have been committed to the development of localized tools. One of the outstanding products is PCD adjustable disc milling cutters.

PCD adjustable disc milling cutter

Zhengzuan PCD adjustable disc milling cutter is mainly used to process aluminum plates and aluminum alloy (imported) materials by plane milling. The product features mainly have the following three points:

(1) High utilization rate-the tool structure is a machine-clamped blade clamping, the blade can be repaired and replaced, and the cutter head can also be reused, which improves the reuse rate of the tool and greatly reduces the customer's use cost;

(2) High machining precision-tool diameter jump ≤ 0.03mm, end jump < 0.003, cutting edge wiper can be increased or decreased according to requirements, milling surface quality is high Ra<0.4, dynamic balance adjustment is convenient, up to n=25000, G≤2.5;

(3) High processing efficiency-PCD cutting edge, the linear speed of different diameters can reach 4000-8000m/min, and the dense tooth structure design can increase the number of tool boxes and improve the processing efficiency.

Processing case

When an aerospace company was milling the outer skin of an aircraft, the original tool used was a D63mm machine-clamped alloy cutter head. The surface roughness of the machine was Ra0.6. There were obvious tool feed marks, and there were problems such as slow cutting speed and low processing efficiency. . After using Zhengzuan PCD adjustable disc milling cutter, the surface roughness of the processed workpiece reaches Ra0.3, which effectively improves the surface quality of the processed part; the processing efficiency is improved. When using this tool to process aluminum alloy parts, the surface width is 550mm , It only takes 3 times to complete the tool stroke; the tool durability has been improved, and the finishing durability can reach more than 5000m.

Xiamen Jinlu Aviation Leaf Disc Solution

The overall blisk structure of aero-engines is complex, the blade profile is a complex free-form surface, the distortion is large, and the machining accuracy is high. The flow channel between adjacent blades is narrow and deep, the blades are thin, and the overall blisk is mostly made of high-temperature alloy and titanium alloy And other difficult-to-process materials. During the machining process, the high cutting temperature and high cutting force are likely to cause tool wear and affect the surface quality of the workpiece, and the deformation of the blade during the machining process is difficult to control, so the overall blisk is difficult to manufacture.

The milling of the blisk starts from the roughing of the runner. Jinlu Tool has launched the SN210 chip-breaking tooth type roughing taper ball nose cutter series of solid carbide end mills. The product adopts a high-performance cemented carbide substrate, combined with advanced PVD coating and cutting edge treatment, and adopts a unique knife design and broken tooth design, so that the tool has high rigidity, excellent vibration resistance, impact resistance and resistance Grindability, long tool life, stable cutting process, suitable for high-efficiency milling processing.

Cycloid machining is a very efficient machining method when roughing some integral blisk runners. The special-shaped taper ball nose tool introduced by Jinlu Tool can realize cycloidal milling of the blisk runner. The product not only has high vibration resistance and high rigidity, but its innovative arc-shaped ball design can achieve a machining efficiency that is 2-4 times higher than that of conventional cycloid machining tools.

When finishing the blisk, the flow path between the blades is narrow and deep, the blade is thin, the twist is large, and the accessibility of the tool is restricted. The end mill often needs to be finished milling with a large overhang. When force acts on the blade, it is easy to deform and tremble. In order to obtain high machining surface quality and stable cutting performance, Jinlu Tool recommends the SN210-TB4 taper ball nose cutter series with taper avoidance design and shock-absorbing design. The tool adopts ultra-fine-grained cemented carbide matrix, with extraordinary wear resistance and rigidity, with special nano-coating and special cutting edge treatment, so that the tool can obtain stable long life and cutting performance, with ultra-high profile accuracy , Suitable for semi-finishing and finishing of the whole leaf disc.

For the finishing of the blade profile with high twist, the SN210-FB4 deep groove ball nose cutter launched by Jinlu Tool can meet the finishing of the blade with high twist. The combination of its one-piece ultra-high profile accuracy, high wear resistance and high rigidity substrate and special nano-coating can not only solve the problem of high distortion processing, but also provide better processing accuracy and tool life.

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