Most of the typical components of aero-engines use difficult-to-machine materials such as titanium alloys and high-temperature alloys. They have high strength and hardness, high toughness and elongation, poor thermal conductivity, large work hardening on the machined surface, and poor cutting performance. Aviation components work in the harsh environment of high temperature, high pressure and high speed. The development of each new product means major changes in the function, structure and materials of the parts. It is also the development task for cutting. Disc parts in typical aerospace parts tend to be thin. In order to ensure the balance of the disc parts at high speed, the dimensional accuracy, positional accuracy, shape error and surface roughness of the main surface are required to be high. Each type of shaft is generally a hollow shaft in structure, and the inner surface is designed with stepped holes according to equal strength conditions, and the inner and outer surfaces are highly coaxial and the wall is thin. The wide application of difficult-to-machine materials in the casing (see Figure 1) and the complexity of the casing structure, the large amount of material removal, the high precision and surface quality requirements, and the long processing cycle all require cutting technology.
Yang Jinfa, senior engineer of AVIC Shenyang Liming Aero Engine (Group) Co., Ltd., in an interview with the metal processing online reporter, pointed out that the main contradiction in the machining of difficult-to-machine materials for aviation has changed from being able to be processed to high efficiency and low cost. Processing.
Aviation machining materials processing characteristics:
(1) Large cutting force and high cutting temperature
Most of the difficult-to-cut materials have high hardness and strength, high atomic density and bonding force, high fracture resistance and long-lasting plasticity, and large cutting force during cutting. Most difficult-to-cut materials not only have high room temperature hardness and strength, but also have high temperature hardness and high temperature strength. Therefore, during the cutting process, the power of cutting deformation is large, the thermal conductivity of the material itself is small, and a large amount of cutting is concentrated in the cutting area. Heat, forming a very high cutting temperature.
(2) The tendency of work hardening is large
Some of the difficult-to-cut materials have high plasticity, high toughness, and high reinforcement coefficient. Under the action of cutting force and cutting heat during cutting, large plastic deformation occurs, resulting in work hardening.
(3) Large tool wear
When cutting difficult materials, the cutting force is large, the cutting temperature is high, the friction between the tool and the chip is intensified, the tool material and the workpiece material have an affinity, the existence of hard spots of the material and the serious work hardening phenomenon, so that the tool Wear occurs during the cutting process, losing the ability to cut.
(4) Chips are difficult to control
The material has high strength, plasticity and toughness, and the chips during cutting are strip-shaped winding chips, which are neither safe nor affect the smooth progress of the cutting process. Due to the unique properties and cutting characteristics of difficult-to-cut materials, chip control is a ubiquitous problem, and cutting can only be carried out smoothly by using reliable chip breaking measures.
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