The hottest and faster end milling of superalloys

2022-07-26
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Faster end milling of superalloys and titanium materials

challenge: for the end milling of aerospace parts made of superalloys, China is still in the deep development stage of industrialization, information, urbanization, marketization and internationalization, and the working time is often too long

solutions: solid carbide end mills and special technologies provide powerful solutions

for aircraft parts, the machining allowance may reach 80% of the weight, which means that the machining cycle is long. Therefore, the processing time is an evaluation parameter that we focus on. Rough machining is mainly to achieve the maximum metal removal rate. Generally, the scheme we adopt is to use large-diameter machine clamping tools for rough machining, and reserve a certain machining allowance for fine milling. Since the processing at this stage accounts for a considerable amount of the total processing time, it is necessary to greatly shorten the processing cycle by optimizing the operation

the remaining allowance shall be machined with carbide end mills. The requirements mainly include good tool life, short processing time, high surface quality and high safety. To meet these requirements, it can be realized by circular arc cutting, small cutting width, multiple teeth, high cutting speed and large cutting depth. The following machining methods are recommended: corner slice milling, narrow groove cycloid milling, etc

cycloid milling is an axial circular motion to achieve controllable circular arc cutting.

in order to reduce weight, the fuselage structural parts often adopt thin-wall structure. This 25 cold-rolled ribbed steel bar is processed in the way of staggered tool path, that is, first, a small cutting depth is processed at one side of the thin wall, and then the normal cutting depth is used to process the thin wall at both sides in a staggered way with the positive 3 sampling rule

solid carbide end mills need to be used on rigid machine tools with flexible operating systems. Use high-precision tool holder to reduce runout (tool life will be reduced by 50% for every 100% increase in runout). When machining titanium and superalloys (HRSA), coolant must be used to improve chip control and limit cutting temperature. If high-pressure internal cooling is used, the performance will be better

it is recommended to use such integral cemented carbide end milling cutter: 50 helix angle, optimized design of chip removal groove according to the number of teeth, sharp edge with positive rake angle, small support surface, edge rounding instead of chamfering, and high-performance coating. In order to improve accessibility and reduce the contact surface with the workpiece to reduce vibration, taper milling cutters are sometimes used

arc cutting, small cutting width, multiple teeth, high speed and large cutting depth are adopted, which is the best way to meet the finishing requirements with integral carbide end milling cutter

summary

integral cemented carbide end milling cutter and its special milling technology provide a safe and efficient quality first solution for aerospace parts processing. (end)

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