AVIC Shenyang Liming Aero Engine (Group) Co., Ltd. Yang Jinfa
Efficient machining of aero-engine components is essential for maintaining high performance and reliability in the aerospace industry. To achieve this, it's crucial to develop a comprehensive evaluation system that takes into account the challenges of machining difficult-to-process materials. This includes analyzing cutting performance based on tool geometry and assessing workpiece machinability from the perspective of the part itself, ensuring an optimal match between the tool and the material.
The machining process for these hard-to-machine materials should be optimized in stages. Roughing operations focus on maximizing machining efficiency, while finishing aims at achieving superior surface integrity without compromising speed. Simulation analysis plays a key role in this process, allowing engineers to predict outcomes before actual production begins. Different processing techniques—such as turning, milling, drilling, and boring—should be studied under various heat treatment conditions for materials like high-strength structural steel, stainless steel, powder superalloys, and titanium alloys.
Based on the specific characteristics of each material, along with the properties of the tools used, engineers must design and select appropriate factors. Through cutting tests, they can optimize high-efficiency cutting parameters and build a practical cutting database that supports consistent and reliable machining.
1. Use High-Performance Machine Tools
Currently, the primary equipment used in aero-engine machining relies heavily on high-performance CNC machines. The demand for multi-axis linkage and composite CNC machining is growing rapidly. Machining simulation is evolving from motion-based simulations to physical simulations, which provide more accurate predictions of real-world performance.
Combining advanced CNC equipment with optimized processing technologies and a well-maintained cutting database is a proven method for achieving efficient and precise machining. Given the complex structure of aero-engine parts, the machine tools must be highly flexible and versatile. They need to handle a wide range of part types, support multi-process composite machining, and enable automation to meet the demands of modern aerospace manufacturing (see Figure 1).
Figure 1: Cutting, Grooving, and Profiling Turning Applications
When selecting cutting tools, it's important to consider both traditional and innovative options. New tool materials and advanced designs are increasingly being used to improve cutting performance and reduce machining time. During the cutting process, data is collected, analyzed, and stored in a database to guide future operations.
High-performance tools, such as the new grooving tool, can replace a significant portion of standard ISO turning tools. These tools are particularly effective for complex surfaces and have become a key focus for many leading manufacturers. As the industry continues to evolve, the use of advanced tools and technologies will remain central to improving efficiency and quality in aero-engine machining.
Figure 2: High Performance Tool
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