The aerospace industry is one of the most demanding industries in the world. The machining challenge facing aero-engine parts is Yan Jun, and the key to its success is to combine the latest application and process knowledge with the best tool solutions.
Turbine disk turbine turning processes are complex and the materials are often difficult to machine alloy materials such as Inconel 718, Waspalloy and Udimet 720. Such parts are often difficult to clear the cavity contour. (1) Tool solution: Modular SL70 tool system. Round inserts are the best choice for roughing and finishing demanding materials with high processing efficiency and good accessibility. These round inserts have a large radius of the tool tip, which means that the main deflection angle can be made smaller without reducing the depth of cut, thus increasing production efficiency. The blade of the modular SL70 tooling system can be designed according to the characteristics of the concave cavity, eliminating the need for non-standard tools or improving the tool. Users have the flexibility to choose from a wide range of adapters and blades, allowing for a wide range of module combinations based on limited tool inventory. These blades take into account axial and radial interference so they can penetrate deep into the chute and with high pressure cooling, and the coolant can act directly on the cutting edge through the inside of the blade. Thanks to its anti-vibration characteristics, high performance is ensured in applications where accessibility is high, so these blades are often able to reduce vibration and obtain longer at higher feed rates when turning deep groove features. Tool life. In addition, the Sandvik Coromant Capto interface provides exceptional rigidity even when using large overhangs or with high cutting forces. (2) Application: Cycloid turning. In the processing of deep slots and grooves, the cycloid is an efficient way of processing in terms of metal removal rate. Through the segmentation of the workpiece, the cycloidal car adopts the method of rolling in and cutting in, which can reduce the blade contact surface. Chip removal is always a key factor when turning grooves. Processing this material has a large shear force and therefore requires the formation of narrower chips, which requires balancing the insert geometry and feed. This also maximizes linear motion so that optimum productivity can be achieved by maximizing feed rates. At the same time, this machining method ensures that the cutting force direction is different each time the tool is retracted. In addition, since the blade never leaves the workpiece, alternate cutting directions can make full use of the cutting edge to make the blade more durable. Cycloid turning avoids chip clogging, reduces vibration trends and residual stress, and is ideal for safe and efficient removal of large quantities of material.
Turbine turbine casings are often made of challenging materials, and the material of the turbine casing is often challenging, such as Inconel or Waspalloy. Due to the large amount of metal removal, it is easy to have a major influence on the part structure (for example, deformation) during milling. These parts require a lot of turning and five-axis methods to remove large amounts of material, resulting in a very long production cycle. (1) Tool solution: ceramic material CC6060. Compared to cemented carbide tools, ceramic cutting tools have higher heat resistance and are less prone to chemical reactions with workpiece materials. The ceramic material CC6060 is an optimized material. For large diameter parts, the CC6060 is suitable for higher feed rates and long-term continuous cutting, making it an ideal choice for milling turbines. Due to its excellent groove wear resistance, the CC6060 is suitable for larger depths of cut than other ceramic materials, ensuring optimum productivity during the initial and intermediate stages of semi-finishing to roughing. . This material is also the first choice for cavity machining and profiling. (2) Application: Ceramic turning between the bosses. During the entire turbine machining process, an average of 75% of the time is spent on the material between the turning and milling bosses. Turning milling involves rotating the workpiece while cutting with a rotary milling tool. This process is ideal for machining turned parts that require high metal removal rates and breakages such as ignition bosses. The boss of the turbine is located at the edge of its cylindrical perimeter. Turning with ceramic tools not only reduces groove wear, but also increases feed rates and achieves higher metal removal rates – the most efficient way to remove material between the studs.
Fan Machines These large titanium alloy parts are less machinable, with complex shapes and thin walls. However, unlike nickel alloys, titanium alloys cannot be processed with ceramics. This makes how to remove metals efficiently becomes a challenge. It is important to machine such parts to maintain low cutting temperatures. (1) Tool solution: Vertical lathe (VTL). In order to ensure temperature control and excellent part accuracy, such processing should be carried out on a vertical lathe. Vertical lathe design requires manual quick change or automatic tool change. Especially with automatic tool change, long chips mean a high risk of component damage. However, on a vertical lathe, coolant can be delivered directly to the spindle through the ram, with no restrictions on coolant pressure, thus improving cutting conditions and process safety. (2) Application: High pressure cooling (HPC). One key to ensuring the success of fan casing processing is the use of high pressure cooling. Benefits of HPC include improved chip control and reduced temperature in the cutting zone. Safer chip control ensures that chips are smoothly discharged from tight cavities and grooves. This ensures that the chips do not wrap around the tool or scratch the part. Efficient cooling of the cutting zone will help minimize tool wear, extend tool life by up to 50%, and increase cutting speed by 20%. After the high pressure pump of the machine has generated pressure, the tool is then required to transfer the coolant to the correct position. With high-precision nozzles, the coolant can be directed to the main cutting edge. This efficient application helps to dissipate heat evenly during cutting.
Disc shafts and fan discs Engine disc shafts and fan discs represent two equally challenging features: deep bore and dovetail tail groove. (1) Tool solution: anti-vibration blade. The use of anti-vibration blades when machining these parts will help solve common vibration and chip removal problems. The anti-vibration blade is designed with a patented anti-vibration device to ensure a safer and more efficient process. The depth of cut can be four times higher than when no anti-vibration device is installed. These narrow strip blades are able to penetrate deep into the bottom of the deep cavity to remove chips efficiently, ensuring an extremely safe machining process. (2) Application: Vibration-free turning in deep grooves. Deep troughs represent one of the most challenging features of such parts. In terms of application, the deep groove of the disc shaft is easy to form a chip accumulation in the concave cavity, which causes a safety hazard of the blade. To ensure process safety, vibration-free turning should be used. The elliptical cross-section of the toothed interface provides outstanding stability and accessibility, while the 3 to 10 inch high blade provides optimum coolant supply to aid chip evacuation.
The shaft generator shaft is made of high alloy steel or Inconel and the main machining challenges it faces are the length of the part and the complex internal features. The most important advancement in the manufacture of shafts is due to the continuous development of multi-tasking machines. (1) Tool solution: SilentTools damping mast. Due to the long length of such parts, vibrations often occur during boring. Vibration can cause, for example, destructive surface textures, insufficient precision, low productivity, increased blade consumption, machine wear acceleration, and noise generation. SilentTools masts have an embedded anti-vibration structure that enables vibration-free machining. At the same time, it can maintain good production efficiency and tight tolerance tolerance requirements. (2) Application: boring deep holes and deep concave cavities in the holes. Boring deep holes can result in poor surface finish and vibration due to instability. The only cutting force that the part does not need to cancel is the axial force. However, radial forces can cause the tool to bend and leave the cutting zone, thereby adversely affecting tolerances and bore diameters. By applying progressively increased axial and radial loads, the current frequency or SilentTools damping absorbing rod absorbs any vibration generated during cutting, which not only improves chip control, but also improves cutting parameters.
The overall leaf disc/impeller has more and more applications in the engine compressor due to its advantages in weight, efficiency and maintenance. Compared to other parts, such parts have narrow cavities, long slots and deep complex geometries that require five-axis linkage when cutting. The key to ensuring the success of the process is a five-axis machine with good dynamics, optimized software and the right tool selection. (1) Tool solution: CoroMillPlura 50 degree spiral angle belt avoidance solid carbide rounded end mill rough machining material for Inconel slot, CoroMillPlura 50 degree spiral angle belt avoidance solid carbide rounded end mill special Suitable for applications where the milling depth is approximately twice the tool diameter and the milling width is small. (2) Application: Cycloid milling. Cycloid milling is a high-speed machining technique used to remove materials from lace and cavities. By smoothly cutting the arc and cutting the workpiece to control the contact arc length of the milling cutter and the workpiece, higher productivity and longer tool life can be achieved. Cycloidal milling combines high table feed with low cutting forces to keep cutting edges and workpieces at a lower temperature. This method uses a thin chip technique, which results in less heat buildup in the chips and the tool can run at full depth. In addition, the number of passes has been reduced. Cycloidal milling is not always the fastest way to roughen a slot, but there is no doubt that it can achieve longer tool life, high predictability and higher part quality.
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