一、 Selection of Processing Materials: Perfect Match between Performance and Application
The materials used in aerospace components need to have characteristics such as high strength, high hardness, and high thermal stability to adapt to extreme working environments. The main materials include:
1. Titanium alloy and aluminum alloy: Titanium alloys such as Ti-6Al-4V have become the preferred choice for high-temperature and high stress components such as aircraft engines due to their excellent high strength to weight ratio and excellent corrosion resistance. Aluminum alloys, especially models such as 2024, 6061, and 7075, are widely used in the aerospace industry due to their low density, high strength, and excellent corrosion resistance. However, these materials are difficult to process and require special techniques for processing.
2. Stainless steel: 300 series and 400 series stainless steel, such as 304 and 17-4PH, have excellent corrosion resistance and certain high-temperature strength, suitable for various application scenarios in the aerospace field.
3. Special alloys: Nickel based high-temperature alloys, cobalt based high-temperature alloys, etc., are used to manufacture high-temperature components such as turbine blades and guide vanes for aircraft engines. The processing difficulty of these materials is extremely high, posing severe challenges to cutting processes.
二、 Process planning: Fine control from rough machining to precision machining
The cutting process of aerospace parts requires precise planning of multiple processes to ensure the quality and performance of the final product.
1. Rough machining: With the goal of efficiently removing excess materials, traditional methods such as side milling, shoulder milling, and end milling, as well as the emerging cycloidal (whirlwind) milling process in recent years, are used to achieve fast and efficient material removal.
2. Semi precision machining: On the basis of rough machining, further improve machining accuracy, adopt end face or side machining methods, adjust cutting parameters appropriately, and lay the foundation for subsequent precision machining.
3. Precision machining: With the goal of obtaining the required high-precision dimensions and excellent surface roughness, end milling is adopted, and precise cutting parameters are used to ensure the final quality of the parts.
4. Composite machining: For complex curved parts, multiple machining methods such as gear hobbing, grinding, etc. are used to ensure that the dimensions and surface quality of the parts meet the design requirements.
In addition, fixture design, thermal deformation control, chip discharge, and other issues need to be considered in the process flow to ensure stable machining quality.
三、 Optimization of Cutting Parameters: Balancing Accuracy, Efficiency, and Cost
The selection of cutting parameters directly affects machining accuracy, surface roughness, and machining efficiency. The machining of aerospace parts requires extremely strict surface quality, therefore comprehensive optimization of cutting parameters is necessary.
1. Surface roughness optimization: By using systematic optimization methods such as Taguchi experiment and response surface methodology, the optimal cutting parameter combination is found to obtain the ideal surface roughness value.
2. Optimization of machining efficiency: By increasing feed rate, cutting depth, and width, cutting efficiency can be improved, but a balance point needs to be found between machining efficiency and tool life to determine the optimal range of cutting parameters.
3. Thermal deformation control: Cutting thermal effects can cause thermal deformation of the workpiece, affecting the dimensional accuracy and shape stability of the part. Therefore, it is necessary to take measures such as optimizing cutting parameters, selecting appropriate types and supply amounts of cutting fluids, and effectively controlling cutting thermal effects. cut
The optimization of cutting parameters is a complex process that requires comprehensive consideration of multiple factors. Modern aerospace companies tend to apply finite element simulation technology and artificial intelligence optimization algorithms to achieve intelligent optimization of cutting parameters.
四、 Development Trend of Cutting Technology: Innovation Leads the Future
The aerospace manufacturing field has always led the development of cutting technology, and there are constantly emerging cutting technologies and processing methods being researched and applied.
1. Cutting technology for difficult to machine materials: Research focuses on improving cutting fluid performance, developing new hard alloy and superhard tool materials, and optimizing cutting parameters for difficult to machine materials such as titanium alloys, stainless steel, and high-temperature alloys.
2. Precision microfabrication technology: With the increasingly small size and complex shape of key components in aerospace products, precision microfabrication technology has attracted much attention. Technologies such as micro milling, micro turning, and integrated micro milling/drilling provide the possibility for precision machining of small parts.
3. Arsenic free processing technology: Traditional metal processing often relies on toxic and harmful cutting fluids, but in recent years, arsenic free processing technology has been increasingly valued. Dry cutting, endowing tool surfaces with nanoscale lubrication properties, and using biodegradable cutting fluids are methods aimed at promoting environmental protection and safeguarding human health.
4. Intelligent cutting technology: Cutting edge technologies such as artificial intelligence and the Internet of Things are gradually being integrated into the field of cutting and machining. By collecting real-time data during the cutting process through sensors and using machine learning algorithms for analysis and prediction, intelligent adjustment and optimization of cutting parameters can be achieved, improving machining efficiency and product quality.
In summary, aerospace component cutting technology is a comprehensive technical system involving multiple fields such as materials science, mechanical engineering, and computer science. With the continuous advancement and innovation of technology, cutting technology will continue to develop towards higher efficiency, precision, and environmental friendliness, providing strong support for the sustainable development of the aerospace industry.
