Aviation difficult-to-machine materials and part cutting technology is a complex system engineering. In the selection of the tool, a new type of high-efficiency tool that matches the mechanical properties, chemical properties and physical properties of the machined part should be reasonably selected. Some high-speed steel tools, carbide coated tools, ceramics and super-hard material tools with excellent performance are the first choice for efficient cutting of typical parts of aviation difficult-to-machine materials.
The following are successful cases of aerospace parts processing:
(1) Processing of a nickel-based superalloy GH4169 ring. This material is equivalent to the US material grade Inconel718, hardness 35 ~ 47HRC. The line speed is 400 m/min, the feed rate is 0.25 mm/r, and the depth of cut is 1.6 mm. When feeding, the new process of oblique cutting is adopted, that is, the depth of cut is gradually reduced during the cutting process, and the effect is good. Not only the blade wear is slight, the shape of the blade is intact, and high-efficiency cutting is realized, and the processing quality is ensured.
(2) A machine part, the material is GH2132. After solid solution and aging, the hardness is higher. The material has a high cutting temperature and a high work hardening tendency, and the depth of the hardened layer can be up to 0.05 mm during cutting, which has an adverse effect on the cutting process. The material has high strength, large plasticity and toughness, and large surface residual stress. The cutting depth and feed rate should be reasonably selected during the cutting process so that the cutting edge is cut under the hardened layer, otherwise the tool wear will be accelerated. The part has a large diameter, a thin wall thickness, and the rigidity of the part is not strong, resulting in an increase in cutting force, vibration occurs during processing, and the part is deformed, and the surface of the part is prone to oscillating ripples. In the cutting test, multiple layering is performed according to the depth of the workpiece.
Test equipment: Five-axis CNC milling machine, the spindle speed of the machine tool reaches 1 800r/min, and the feed speed reaches 500~700mm/min.
Test tool: Select solid carbide end mill with diameter of 12mm, equidistant 4 teeth, main declination 90o, shank diameter 12mm, helix angle 45o, blade length 26mm, knife length 75mm, TiALN coating, high pressure cooling . The 45o helix angle can effectively increase the space of the chip. The cutting edge and the helix angle of the milling cutter are reasonably optimized, the cutting force is reduced, the tool life is prolonged, and the surface quality of the part meets the technical requirements.
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