Xi'an Aviation Power Control Company Zhao Xinglong
Zhao Xinglong, Xi'an Aviation Power Control Company

Aeroengine components operate in extremely harsh environments, such as high temperature, high pressure, and high speed. With the continuous advancement of aero-engine technology, more and more composite materials are being used in modern engines. High-strength, high-temperature resistant alloys, powdered alloy steels, single-crystal alloys, and lightweight composite materials have significantly increased the difficulty of cutting processes, requiring more advanced and precise machining techniques.

1. Machining of Nickel-Based Superalloy Parts

Nickel-based superalloys are widely used in aerospace due to their excellent oxidation resistance, high-temperature deformation resistance, and good welding performance. They are ideal for manufacturing long-term operating high-temperature bearing parts and hot-end components of aircraft engines, typically working below 650°C. However, challenges like numerous hard spots, poor thermal conductivity, and significant work hardening tendencies make them difficult to machine. While many studies have been conducted on superalloy cutting, there is still limited research on tool selection, coating performance, and parameter optimization for nickel-based superalloys, making on-site processing quite challenging. The part shown in Figure 1 is made of GH2132 material, with dimensions of φ10mm × 2000mm, a hardness of 320 HBS, and a batch size of 500 pieces per month. The required surface roughness is Ra = 1.6μm, and the aspect ratio is 18, typical of a slender shaft part.

Figure 1: Slender Shaft Parts
Figure 1: Slender Shaft Parts

Without a central hole, traditional CNC lathes are not suitable for this type of machining. Therefore, a CNC vertical slitting automatic lathe, model CKN1120IV from Sichuan Pushinjiang Machine Tool Co., Ltd., was chosen. Based on the specific characteristics of nickel-based superalloys and the equipment's capabilities, several conclusions were drawn from cutting tests: 1. The MT09T304-PM5-WSM30 coated tool is highly suitable for machining nickel-based superalloys. 2. For GH2132, the main rake angle should be between 40°–50°, the secondary rake angle between 0.5°–3°, and the lead angle between -10°–-20°, which helps avoid built-up edge and ensures good surface quality. 3. A cutting speed of 95–120 m/min and a feed rate of 0.1–0.15 mm/r can achieve the required Ra = 1.6 μm surface finish.

2. Machining of Powdered Superalloy Parts

The oil pump gear is a critical hot-end component of an engine, operating under extremely demanding conditions. To ensure reliability and stability, European and American countries often use powdered high-temperature alloy steel, which has fine grain structure, uniform organization, no obvious segregation, and high alloying degree, resulting in excellent fatigue resistance. It is the preferred material for high-performance engine gears and turbine disks. When grinding the high-vanadium powder metallurgy alloy steel AHP-10V, issues such as surface roughness and cracks at the grinding end face have long been problematic. The part shown in Figure 2 is made of AHP-10V, with a surface hardness of ≥65HRC and a core hardness of 30–45HRC. After the grinding process, all external surfaces achieved a surface roughness of Ra = 0.1μm, meeting the drawing requirements.

Figure 2: Parts to Be Processed
Figure 2: Parts to Be Processed

These case studies highlight the importance of selecting appropriate tools, optimizing cutting parameters, and understanding material behavior when dealing with complex aerospace components. As the industry continues to evolve, further research and innovation in machining technologies will remain essential to meet the growing demands of modern aero-engine production.

Other

kaiping aida sanitary ware technology co.,ltd , https://www.kpaidafaucets.com

Posted on