High-performance processing technology is a key technology for the processing of critical aerospace parts, driving the aviation manufacturing industry towards higher production efficiency and processing quality. This technology provides technical support for the high-quality development of critical aerospace parts by improving the production efficiency and processing accuracy of the processing process. The advantages and application fields of high-performance machining technology are introduced, and the research progress of scholars in high-performance machining technology in the aerospace field is summarized, including high-speed machining technology (HSM), multi-axis linkage machining technology, micro-machining technology and typical Aerospace materials processing. At the same time, the challenges and development trends that the technology may face in the future are also prospected.
Preface
01
The aerospace manufacturing industry is at the forefront of high-performance processing technology and has strict requirements on the performance and accuracy of mechanical parts, especially those used under harsh conditions such as high temperature and high pressure [1]. The manufacturing of these parts relies on accurate and reliable high-performance machining technologies, such as high-speed machining, multi-axis machining, micro-machining and processing of typical aerospace materials. These technologies not only improve production efficiency and reduce costs, but also ensure the quality and performance of parts [2].
In the aerospace field, key parts such as impellers, blades, casings and thin-walled parts are usually made of high-performance alloys, with complex designs and extremely high precision requirements [3]. In addition, these parts are prone to deformation during processing, especially thin-walled parts, so high-performance processing technology is very important when manufacturing these critical parts. These technologies can not only handle difficult-to-machine materials, but also ensure product quality and performance under extreme working environments and complex design requirements, while achieving micron to nanoscale machining accuracy [4], especially in the production of impellers, blades and casings In terms of critical and heavy items, it has demonstrated significant advantages.
In summary, the application of high-performance processing technology in the aerospace field not only improves manufacturing efficiency and product quality, but also drives the development of new materials and innovative designs. This is critical to meeting the stringent standards and complex manufacturing requirements of the aerospace manufacturing industry.
High-performance technical processing connotation
02
High-performance machining technology is an engineering technology that integrates key elements such as high-speed machining technology (HSM), multi-axis linkage machining technology, micro-machining technology and difficult-to-machine material technology, aiming to improve material processing efficiency, accuracy and performance. The framework is shown in Figure 1. In the aerospace field, these technologies are used to manufacture high-demand parts to cope with complexity and reliability requirements, driving the continuous advancement of manufacturing technology in this field.
Figure 1 High-performance machining technology framework
2.1 High-speed processing technology
High-speed machining technology in the aerospace sector plays a key role in producing precision and complex parts. It shortens the production cycle and improves the surface quality of the parts by increasing the material removal rate and optimizing the machining path. In high-speed milling, solid and indexable ball-nose end mills are used to process complex structures on convex and concave surfaces and five-axis CNC milling machines. The milling operations are shown in Figure 2, which reflects the diversity and complexity of technology [4].
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a) Milling convex surface b) Milling concave surface
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c) Milling complex structures
Figure 2 Milling processing under different working conditions [4]
For the specific material TC4 titanium alloy, Wang Sheng et al. [5] achieved significant improvements in processing efficiency and surface quality by optimizing the milling parameters of PCD tools. Research by LUIS et al. [6] found that in complex surface milling, the maximum radial depth, feed amount and downward cutting strategy are crucial to improving surface quality and productivity. VOGEL et al. [7] developed an advanced tool holder with an internal particle filling structure. The tool holder was tested for turning at Monfort Company, as shown in Figure 3. By reducing vibration during titanium alloy machining, the machining efficiency and tool holder were improved. life.
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a) Test setup
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b) Tool handle structure
Figure 3 Filled toolholder test setup and toolholder structure [7]
In addition, the application of advanced CAM systems, such as Mastercam, UnigraphicsNX and CATIA, provides diverse tool path strategies for machining [8]. HASCOET and RAUCH [9] used OpenNC controller and NURBS tool path interpolation to further improve the quality and efficiency of high-speed machining, bringing significant progress to the aerospace manufacturing industry.
2.2 Multi-axis linkage processing technology
In the aerospace industry, multi-axis linkage machining technology, especially the application of four-axis and five-axis CNC machine tools, has significantly improved the production efficiency and quality of key parts and brought significant innovation.
In terms of specific application research, FAN et al. [10] developed a five-axis machining method specifically for centrifugal impellers. This method divides the impeller into different areas and optimizes the tool path to achieve accurate and efficient milling. MHAMDI et al. [11] developed a dynamic model for multi-axis milling of aeroengine blades Ti-6Al-4V, achieving better accuracy and surface quality in blade manufacturing and solving complex shape and material challenges. Chen Kaihang [12] developed a semi-real-time speed planning method for five-axis linkage CNC machining of impellers, which effectively improved the processing quality and efficiency and met the actual needs of the project. Taking the semi-open integral impeller as an example, the multi-axis linkage processing site and samples are shown in Figure 4.
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a) Impeller finishing process
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b) Semi-open integral impeller
Figure 4: Multi-axis linkage processing site and sample parts
In addition, Wenhao et al. [13] developed a new method for generating tool axis vectors for grid surface machining to improve the efficiency and accuracy of multi-axis CNC cutting. Wang Bo et al. [14] developed a method for modeling the micro-element trajectory of the cutting edge in multi-axis ball end milling. They constructed a dynamic model integrating tool geometric characteristics to accurately predict milling forces.
Multi-axis linkage machining technology is increasingly widely used in the aerospace field, and its improvement in production efficiency and manufacturing quality cannot be ignored. The development and application of this technology has opened up a new path for further innovation in the aerospace manufacturing industry in the future.
2.3 Micromachining technology
In the aerospace field, micro-machining technologies, especially micro-milling, micro-electrical discharge machining, laser micro-machining and ultrasonic machining, play a vital role. These technologies play a key role in manufacturing microscopic components with complex shapes and high precision requirements.
Micromilling technology shows advantages in manufacturing micro-components with high precision and complex geometries. Tian Lu et al. [15] made progress in the optimization of minimum cutting thickness and cutting force, while L I et al. [16] developed a new micro-nano composite ceramic tool material Ti(C, N)/WC for micro milling cutters. /ZrO2, effectively improves the bending strength, toughness and hardness of cutting tools. In addition, Zhang Xinxin et al. [17] optimized the high-speed micro-milling cutting parameters of tough materials such as titanium alloy and stainless steel, improving the surface quality and processing efficiency of these difficult-to-machine materials.
In the field of micro-electrical discharge machining, Tagawa [18] confirmed the effect of micro-electrical discharge machining in improving the processing efficiency and surface quality of Ti-6Al-4V titanium alloy. LIN et al. [19] optimized the micro-milling EDM of Inconel 718 through the Taguchi method, achieving a balance between electrode wear, material removal rate and working gap, thereby improving the cutting efficiency. HUU et al. [20] used carbon-coated electrodes to improve the processing efficiency of titanium alloys, demonstrating the potential of non-contact machining in hard materials. The research of GARZON et al. [21] focuses on force measurement technology in micro-EDM, which provides more accurate monitoring of the machining process. The combined processing platform built and optimized for this device on the Sarix sx200 machine tool is shown in Figure 5.
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Figure 5 Combined processing machine tool: micro milling + micro EDM [21]
The development of laser micromachining technology has significantly improved the local processing performance of various materials. As shown in the research of CHAVOSHI [22], the local processing of various materials through high-energy laser beams improved the processing performance. Xiao Qiang et al. [23] successfully manufactured micro-nano structures using femtosecond laser processing. SUN et al. [24] used µCT to detect void defects in Ti-6Al-4V manufactured by laser additive manufacturing, which provided important information for aerospace quality assurance.
At the same time, ultrasonic processing technology has also made important progress. The high-speed ultrasonic wave cutting technology developed by Peng Zhenlong et al. [25] improved the cutting speed and efficiency of difficult-to-machine materials, while ZHAO et al. [26] used a self-developed RUVAG device based on workpiece vibration to conduct a single CBN grain grinding test. , aiming to reveal the material removal mechanism and wear performance of CBN grains by radial ultrasonic vibration. The ultrasonic-assisted pecking drilling (UPD) method proposed by LIU et al. [27] effectively improved the drilling efficiency and quality of CFRP/Ti laminate materials.
The comprehensive application of micromachining cutting technologies not only demonstrates their unique advantages, but also shows great potential in the manufacturing of micro-components with high precision and complex designs. As micro-cutting technology continues to develop, it will continue to promote progress in the aerospace and other precision manufacturing industries.
2.4 Typical aviation difficult-to-process materials
In the aerospace industry, research on precision machining technologies for typically difficult-to-machine materials such as titanium alloys, aluminum alloys, and carbon fiber composites is crucial. These materials play an important role in the manufacturing of critical aviation parts due to their excellent mechanical strength and corrosion resistance, but they also bring processing challenges.
In the field of titanium alloy processing, Tian Rongxin et al. [28] proposed a process parameter optimization method for high-speed milling of TC11 titanium alloy. Liu Peng et al. [29] developed a mathematical model to optimize the cutting force of high-speed milling of TA15 titanium alloy with PCD tools and verified its effectiveness. HOURMAND et al. [30] found that coated tungsten carbide (WC or WC/Co) tools performed better in terms of wear, smoothness, life and friction than uncoated tools. EZUGWU et al. [31] found through research that when using PCD tools for high-speed precision turning TC4, high-pressure cutting fluid can significantly improve surface smoothness and tool life and reduce physical damage. In addition, Yao Jun et al. [32] effectively improved the processing efficiency and reduced costs of TB6 titanium alloy by applying vibration electrolytic cutting technology.
In terms of aluminum alloy processing, DONG et al. [33] focused on studying the wear of diamond tools in precision machining, highlighting the influence of tool clearance and feed speed. WANG et al. [34] studied the cutting processing of 7050-T7451 aluminum alloy and showed that larger rake angles and thicker chips can significantly reduce energy consumption, thereby achieving more efficient and environmentally friendly manufacturing. In addition, JAROSZ et al. [35] significantly reduced the AL-6061-T6 aluminum alloy processing time (about 37%) and improved processing efficiency by optimizing CNC face milling parameters.
In addition, for aerospace carbon fiber material processing, WU et al. [36] developed polycrystalline diamond cutting tools for carbon fiber reinforced plastics (CFRP), which improved cutting efficiency and quality. The stochastic model developed by ZHANG et al. [37] can accurately predict the cutting force of milling fiber-reinforced composite materials, which is of great significance for improving the processing accuracy and efficiency of composite materials. WU et al. [38] used finite element models and Deform 3D software to conduct simulation analysis to solve the drilling problem and improve the processing quality.
To sum up, in the aerospace field, processing technology of typical difficult-to-machine materials is the key to achieving high-performance manufacturing of critical aerospace parts. The development of these cutting technologies not only improves processing efficiency and accuracy, but also opens up new possibilities for the cutting, processing and forming of other new difficult-to-machine materials.
High-performance technology machining application cases
03
3.1 Multi-axis machining of impeller blades
Taking the five-axis machining of an aviation integral impeller as an example, the milling method of the complex surface geometry of the integral impeller blades is considered in advance, and the point milling method and the side milling method are used. Then, consider the selection of cutting tools during finishing of adjacent blades to avoid overcutting and undercutting, and select a tapered shank milling cutter and combine it with the distance analysis function of CAD for analysis. Then, the tool position trajectory is designed through the "blisk" mode of PowerMill software. Finally, in order to ensure the safety and reliability of five-axis machining, the simulation software VERICUT is used to simulate the overall impeller machining to ensure that the machining is safe and reliable and meets the size and accuracy requirements [39]. The key issues and methods are summarized as follows.
1) Ensuring the overall impeller processing efficiency and accuracy is the key to processing technology. The point milling method and the side milling method are used in the milling process, and the blade curved surface is processed step by step along the blade streamline direction through point contact and line contact. Using this processing method ensures processing efficiency and surface quality.
2) To prevent the tool from overcutting or undercutting during finishing of adjacent blades, combine the analysis of the tapered shank end mill and CAD software to determine the minimum spacing of the blades, reserve the machining allowance and the swing angle of the cutter axis, which not only improves the processing efficiency, The tool rigidity is also enhanced.
3) Reasonable design of tool path is the most important step in multi-axis machining. Use the "blisk" module of PowerMill software to construct auxiliary surfaces through parameterized settings and strategy design, and conduct collision and overcut inspections to formulate efficient and reasonable tool position trajectories, and achieve good results in subsequent actual processing.
4) In order to ensure the safety and reliability of five-axis machining, VERICUT simulation software is used to simulate the actual machining environment and process tooling, and combined with the tool trajectory in the CNC program, the feasibility of processing the overall impeller is verified.
3.2 Processing of high-hardness thin-walled ring parts of engine casing
In view of the deformation, vibration and surface quality problems that are prone to occur during the processing of the thin-walled special-shaped structure mounting ring of the aircraft engine casing, a number of measures have been taken to prevent deformation. First, the rough milling process is added to release the machining stress in advance. Secondly, the elastic diaphragm structure expansion tooling and cycloidal turning processing method are used to effectively avoid part deformation. Finally, turning instead of grinding is used to ensure the surface quality and size of the coating, thereby solving key issues in machining [40]. The key issues and methods are summarized as follows.
1) It is key to reduce stress and deformation during subsequent processing and improve the efficiency and quality of the entire manufacturing process. The excess material on the end face is removed through the rough milling process to release processing stress and reduce deformation, while leaving the necessary margin for finishing. This process not only improves the processing efficiency, but also reduces the internal stress through stress relief annealing, ensuring the accuracy and quality of the parts.
2) In order to solve the problem of serious deformation of parts during processing. By designing special tooling and adopting efficient turning technology (see Figure 6), deformation during the processing is effectively controlled, ensuring processing accuracy and part quality. This method is suitable for processing similar high-hardness thin-walled special-shaped parts, which can improve processing efficiency and reduce tool wear while ensuring the surface quality and size of the coating.
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a) Elastic clamping structure clamp
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b) Trochoidal turning diagram
Figure 6: Fixture and cycloid turning [40]
3) In order to deal with the problem that the grinding process produces large vibrations, which causes vibration marks on the coating surface and makes it difficult to meet the surface roughness requirements, the turning process is adopted instead, using special turning tools and reasonable processing.
parameters for processing. Compared with wheel grinding, the contact area of turning coating is smaller, which effectively reduces vibration, improves the surface quality and dimensional accuracy of the coating, and meets manufacturing requirements.
Conclusion
04
This article provides a comprehensive review of high-performance machining technologies in the aerospace field, highlighting the important role of these technologies in aerospace manufacturing. Emphasized the importance of high-performance machining technology in improving the production efficiency and quality of critical parts and ensuring performance under extreme conditions, and then introduced specific application examples to demonstrate the role of these technologies in improving machining accuracy and reducing deformation and vibration. significant advantages. However, in the rapidly developing aerospace field, high-performance processing technology still faces multiple challenges. The future aerospace manufacturing industry will focus on integrating innovative technologies such as digital twins and smart manufacturing, while focusing on environmental sustainability and promoting the development of greener materials and processes. More efficient, intelligent and environmentally friendly technologies will drive the arrival of a new era. .
