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Types of tools for typical parts in the aerospace industry
Aerospace components not only use many new structures, new technologies and new materials, but also have complex configurations and poor rigidity. These factors require the machining of parts such as engines to be processed in large quantities using high-performance standard tools and special tools.
At present, the ratio of high-performance hard alloy standard tools and hard alloy non-standard tools in the processing of engine disk parts, shaft parts and machine parts is equivalent. Typical small and medium-sized components, blade parts, etc. are mainly standard tools. In the actual machining, the selection of the tool mainly considers the following factors: workpiece material, workpiece shape, processing requirements, machine tool, system rigidity, surface quality technical requirements.
Taking turbine casing parts as an example, it is analyzed from workpiece materials, and difficult-to-machine materials such as deformed superalloys and cast superalloys are widely used. These difficult-to-machine materials have small thermal conductivity, high specific strength, high cutting temperature, and are prone to work hardening. The cutting tool wears quickly, the tool life is short, and the tool consumption is large, so the tool geometry angle must be selected reasonably. From the perspective of the structure of the workpiece, the wall is thin, the rigidity is poor, and it is difficult to process.
When machining the raised part of the part, the tool system easily interferes with the part and fixture. Therefore, the tool path must be optimized, such as insert milling instead of side milling, idle travel, optimized tool position, and helical interpolation. From the choice of machine tools, turbines need to be machined in high-power machining centers. From the analysis of the processing steps, the machine needs to be roughed, semi-finished and finished. In order to save the cost of the tool, high-performance ceramic milling cutters can be used for roughing, and standard carbide tools and non-standard high-performance special tools for semi-finishing and finishing, which can significantly improve production efficiency. . In terms of processing economy, the tool configuration plan needs to be continuously improved, and the latest products developed by the tool manufacturer should be used as much as possible.
Common tool materials for aerospace manufacturing
With the wide application of aerospace difficult-to-machine materials, how to correctly select tool materials for cutting, reduce processing costs, and increase productivity is a very important issue. The cutting tool material should match the mechanical properties, physical properties and chemical properties of the workpiece.
With the combination of tool technology and machine tool technology, the mutual improvement of workpiece materials and tool materials, the aerospace manufacturing industry continues to develop. It can be said that the continuous development of tool materials is the driving force for the continuous development of aerospace manufacturing. At present, there are thousands of tool materials widely used in the aerospace industry. According to the tool materials, there are only a few categories: tool steel (carbon tool steel, alloy tool steel, high speed steel), and hard alloy. , ceramic and superhard tool materials. Carbon tool steel is suitable for the manufacture of hand tools, and carbon tool steel T10A and T12A are widely used.
In the aviation industry, cemented carbide tools account for the largest proportion. Carbide tools are the leading tool in aerospace manufacturing, and their application range is quite extensive, which is dominant in CNC tool materials. Cemented carbide has become the main tool material, which enables the cutting process to achieve the transition to the hard alloy era. Due to the different performance characteristics of different grades of cemented carbide, its application range is also different. Cemented carbide can be used not only for the manufacture of a variety of machine-clampable indexing tools, but also for the manufacture of integral end mills, reamers, taps and drill bits. Carbide tools are classified into ordinary hard alloys, coated hard alloys, ultrafine grained hard alloys, and carbon (nitrogen) titanium based hard alloys.
YT type cemented carbide has most of the excellent properties of YG and YW, and is widely used in aviation manufacturing. Coated cemented carbide has higher hardness, wear resistance and heat resistance than the matrix, and is widely used. Ultrafine particle cemented carbide can be used in a wide range of interrupted cutting. Carbon (nitrogen) titanium-based cemented carbide is mainly used for finishing and semi-finishing of continuous surfaces of steel.
At present, the application of ceramic knives in China is still in its infancy, and the actual application development is slow. Ceramic tools are mainly used for roughing workpieces that are difficult to cut with carbide tools. The aviation manufacturing industry has not been able to promote the use of ceramic tools for a long time. It needs to accumulate experience in the geometric parameters, cutting amount and use technology of ceramic tools. Ceramic materials have higher hardness, hot hardness and wear resistance than hard alloys. Ceramic cutters are superior to hard alloys in chemical stability and oxidation resistance, and are very suitable for dry continuous high-speed machining of high-temperature alloys, hardened steel, bearing steel, high-strength steel and other difficult-to-machine materials. There are many applications of high-temperature alloys in aero-engines, and there are many disc-type parts, which is where ceramic tools play their advantages. Achieving efficient machining and replacing some of the carbide tools with ceramic tools is completely feasible. Ceramic knives are not versatile tools, and they can only be fully utilized if they are used correctly.
Aero Engine Enterprise Improves Tool Cutting Technology Level and Reduces Tool Cost Measures 1. Change concepts and grasp the latest development direction of cutting technology
Give full play to the advantages of imported tools and domestically produced tools, standard tools and non-standard tools, give full play to the processing capabilities of various grades of equipment, and select tool suppliers in a targeted manner. The use of domestic tools for complex tools such as thread cutters can effectively reduce costs and ensure quality. The aerospace engine parts (such as the shaft and the casing) have complex shapes and high surface integrity requirements, and the cutting technology needs to be continuously improved. New tools are also emerging, resulting in ever-increasing cutting speeds. We must learn from the concept of high speed, large feed and small depth of cut in advanced European tools, and integrate with international advanced cutting concepts to develop advanced cutting technology.
2. Realize tool re-grinding and reduce procurement cost
In CNC machining, tool damage not only affects the quality and efficiency of the process, but can also lead to serious machine and personal accidents. The damage of the tool is both worn and damaged. When the product is processed, the tool is subjected to cutting force, cutting heat and friction, and will gradually wear or break, and finally lose the cutting ability.
Aero-engine enterprises should formulate the technical standards for tool grinding according to the production characteristics, and strictly follow the tool grinding technology standards to grind the tools and track the quality after coating. In the actual application process, the efficiency of the return grinding tool is very significant. For example, in an engine manufacturing enterprise, the purchased tool is ground with a solid carbide milling cutter, a drill bit, a reamer, a reaming drill and a complex cutter. . The annual purchase of re-grindable carbide end mills is about 50,000 to 60,000. These tools can be used after re-grinding, and the cost of cutting tools is also considerable.
3. Strengthen basic training and implement the project
Strengthening the training of technicians and operators in cutting technology, tool selection, tool use, etc., and improving their ability to select tools and use tools is a prerequisite for cost reduction and efficiency.
Common tool materials for aerospace manufacturing
Abstract With the continuous development of aerospace manufacturing industry, the main structural parts such as blades, disc shafts and casings are made of new difficult-to-machine materials. The problem of efficient processing of these difficult-to-machine materials has always been the subject of enterprise research. The use of high-performance tools in aerospace companies, making aviation...
With the continuous development of aerospace manufacturing industry, the main structural parts such as blades, disc shafts and casings are made of new difficult-to-machine materials. The problem of efficient processing of these difficult-to-machine materials has always been the subject of enterprise research. The use of high-performance tools in aerospace companies has led to the rapid development of machining technology in the aerospace industry, but it is easy to buy good tools and it is difficult to use good tools. Research on cost reduction and efficiency improvement in aviation manufacturing has become a top priority.