AVIC Shenyang Liming Aero Engine (Group) Co., Ltd. Yang Jinfa
Efficient machining of aero-engine components demands a thorough evaluation system tailored for the processing of difficult-to-machine materials. This involves assessing tool performance based on cutting angles and evaluating workpiece machinability from the perspective of the final part. The goal is to achieve an optimal match between the material, the tool, and the machining process. Machining such materials should be approached in stages—roughing focuses on maximizing efficiency, while finishing emphasizes surface quality and maintaining high productivity. Simulation analysis plays a key role in optimizing each step of the process.
Research should focus on various machining techniques, including turning, milling, drilling, and boring, applied to high-strength structural steel, stainless steel, powder superalloys, and titanium alloys under different heat treatment conditions. Based on the material properties, machining characteristics, tool materials, and geometric parameters, it's essential to design and select appropriate factors. Conducting cutting tests and optimizing high-efficiency cutting parameters will help build a practical and reliable cutting database.
1. Use High-Performance Machine Tools
Modern aero-engine machining relies heavily on advanced CNC machine tools. There is a growing demand for multi-axis and composite CNC systems, with simulation evolving from motion-based to physical-based models. Combining high-performance equipment with advanced processing technologies and a comprehensive cutting database is a proven method to enhance machining efficiency. Given the complex geometry of aero-engine parts, the machine tools must be highly flexible and adaptable, capable of handling multiple types of components, as well as supporting multi-process and automated operations to meet the needs of efficient production (see Figure 1).
Figure 1: Cutting, Grooving, and Profiling Turning Applications
When selecting tools, it's important to consider both traditional and innovative tool materials, as well as the latest tool designs. Emphasis should be placed on the cutting performance of new materials and tools to boost processing efficiency. During the cutting process, test data is collected, and information on tool selection, parameters, and cutting conditions is stored in a database. High-performance tools, such as the new grooving tool, can replace a significant portion of standard ISO turning tools, offering superior results in surface finishing for complex parts. Many top tool manufacturers highlight these advanced solutions as their premium offerings (see Figure 2).
Figure 2: High Performance Tool
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