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Cutting tools for aerospace parts must have sharp cutting angles, strong cutting edges, heat-resistant surface coatings, and cutting methods other than general materials to reduce the effective temperature of the processing area and rapid heat dissipation. The main cutting tools for typical parts of aero-engines are mainly imported high-performance cutting tools and non-standard special tools. An example of the inner cavity of a non-standard tool turning disk part is shown in the figure.
Example of inner cavity of non-standard tool turning disk parts
Well-known large tool companies are constantly improving their tool materials, geometric angles, coating technology and processing methods for difficult-to-machine materials to meet the requirements of the aviation industry. The key technology for efficient cutting is the rational application of a series of efficient tool materials and their corresponding cutting parameter optimization techniques.
(1) Select tool materials
The development of tool materials and coating technology has promoted the continuous improvement of tool cutting speed, and tool material is the key to affect tool cutting performance. The tools used in the aerospace industry should have optimized geometry and tool structure; high hardness and wear resistance, high strength and toughness; good thermal stability and thermosetting, good high temperature mechanical properties; Smaller chemical affinity; higher reliability, higher mounting accuracy and repeatability; good chip breaking, chip and chip removal performance, good interchangeability and quick change, resulting in serialization, standardization and Universal.
Common tools for typical parts of the aviation industry include hard alloys and coated tools, ceramic tools, polycrystalline diamond (PCD) tools, cubic boron nitride (CBN), and polycrystalline cubic boron nitride (PCBN) tools. Common coating materials are shown in the attached table.
The tools used in the aerospace industry must adapt to the condition of the equipment, and must also take into account the characteristics of aerospace components and difficult-to-machine materials, while also achieving efficient cutting. It is very important to choose a tool that matches the mechanical, chemical and physical properties of the part being machined.
(2) Tool geometry should be reasonable
Selecting reasonable tool geometry parameters and cutting amount, it is necessary to not only play the cutting performance of the tool material, but also ensure a certain tool durability, so that the cutting is smooth, and high processing efficiency and processing quality are obtained. The cutting performance at any point on the cutting edge depends on the geometric values ​​of the rake angle, the back angle, the lead angle and the rake angle. The tool front angle is increased, the tool is sharp, and the cutting force is reduced, which is beneficial for reducing the deformation of the part. However, the front angle is too large to weaken the strength of the tool tip, the lead angle is increased, the radial cutting force is reduced, and the axial cutting force is increased. Big. An important condition for the development of indexable tools is the development of blade chipbreakers. The new chip breaker structure not only functions as chip breaking and chip removal, but also effectively reduces cutting force and cutting heat.
(3) Optimize cutting amount and improve cutting efficiency
　 Processing efficiency and cost depend on the reasonable choice of cutting amount. The cutting parameters are determined based on the tool material and geometric angle that have been selected to determine the depth of cut feed and the cutting speed. The principle of setting the amount of cutting is to maximize the metal removal rate while ensuring processing quality, reducing cost, increasing productivity, and not exceeding the rigidity of the machine tool system. Among the cutting depth, feed rate and cutting speed, the most important influence on the tool durability is the cutting speed, and the smallest is the cutting depth. Therefore, when determining the amount of cutting, try to choose a larger cutting depth, secondly select the feed amount, and finally determine the cutting speed, so that the metal removal rate can be maximized under the premise of ensuring a certain tool life.
The cutting depth should be determined according to the machining allowance, and the rough and finishing allowances should be reasonably distributed, not only to ensure the surface quality of the parts but also to improve the metal removal rate.
After the cutting depth is selected, the feed amount should be selected according to the surface roughness requirements, according to the material of the part, the radius of the arc of the tool tip, the tool declination, and the cutting speed. Should try to choose a larger feed, its reasonable value should ensure that the machine tool, the tool will not be damaged due to too much cutting force.
When the cutting depth and feed rate are selected, the maximum cutting speed should be selected on this basis. This speed is mainly limited by factors such as tool life and machine power.
(4) Adopt effective cooling measures
　 The cooling performance of the cutting medium depends on the nature of the cutting medium itself, such as thermal conductivity, specific heat capacity, heat of vaporization and vaporization speed. Secondly, it depends on the mode of action of the cutting medium, such as injection flow rate, injection speed, injection angle and other factors. . Part deformation due to heat of cutting should be avoided during cutting. The cutting fluid usually has lubrication, cooling, chip removal and rust prevention functions during wet cutting. The cooling method is generally divided into external cooling and internal cooling. Internal cooling allows the cutting fluid to act directly on the cutting edge, eliminating downtime caused by adjusting the cooling tube. The cutting fluid is effectively and timely supplied, taking away a lot of cutting heat and increasing tool life. In addition, the use of high pressure cooling and ultra high pressure cooling is more beneficial to improve tool life and processing quality. Dry-type and quasi-dry cutting methods such as low-temperature air-cooling and low-temperature micro-lubrication are often used for high-speed cutting difficult-to-machine materials.
　 In short, when cutting aviation difficult-to-machine materials, it is necessary to optimize the tool around the new cutting tool structure and new cutting technology.
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