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

Aeroengine components operate in extremely harsh environments characterized by high temperatures, high pressures, and high rotational speeds. As aero-engine technology continues to evolve, more advanced composite materials are being introduced into new engine designs. These include high-strength, high-temperature resistant alloys, powdered alloy steels, single-crystal alloys, and lightweight, high-strength composites. While these materials offer improved performance, they significantly complicate the machining process and demand more sophisticated processing techniques.

1. Machining of Nickel-Based Superalloy Parts

Nickel-based superalloys are widely used in aerospace applications due to their excellent oxidation resistance, high-temperature deformation resistance, and good weldability. They are ideal for manufacturing long-term operating high-temperature bearing parts and hot-end components of aircraft engines that function below 650°C. However, challenges such as numerous hard spots, poor thermal conductivity, and significant work hardening tendencies often hinder on-site machining. Although many studies have been conducted on the cutting of superalloys, there remains limited research on optimal cutting parameters, tool selection, and tool wear analysis for various coated tools when machining nickel-based superalloys. This lack of guidance makes the actual machining process particularly challenging. The part shown in Figure 1 is made from GH2132 material, with dimensions of φ10mm × 2000mm, a hardness of 320HBS, and a batch size of 500 pieces per month. The required surface roughness after machining is Ra = 1.6μm, and the aspect ratio of the part is 18, making it a classic example of a slender shaft component.

Figure 1: Slender Shaft Part
Figure 1: Slender Shaft Part

Without a central hole, conventional CNC lathes are not suitable for this kind of machining. Therefore, the CKN1120IV vertical slitting automatic lathe produced by Sichuan Pushinjiang Machine Tool Co., Ltd. was selected. Based on the unique characteristics of nickel-based superalloys and the specific requirements of the machine, several key findings were obtained through cutting tests and analysis: 1. The MT09T304-PM5-WSM30 hard-coated tool is well-suited for machining nickel-based superalloys. 2. For the machining of GH2132 blades, the main rake angle is typically set between 40° and 50°, the secondary rake angle between 0.5° and 3°, and the lead angle between -10° and -20°. This configuration helps avoid built-up edge formation 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 a surface roughness of Ra = 1.6 μm or better.

2. Machining of Powdered Superalloy Parts

The oil pump gear is one of the critical hot-end components in an engine, operating under extremely demanding conditions. To ensure the reliability and stability of the aero-engine, developed countries in Europe and the U.S. use powdered high-temperature alloy steel. This material features a uniform microstructure, fine grain size, no obvious segregation, high degree of alloying, and excellent fatigue resistance, making it the preferred choice for high-performance engine components like gears and turbine disks. When machining AHP-10V high-vanadium powder metallurgy alloy steel, issues such as surface roughness and cracks at the grinding end face have long been problematic in on-site production. The part shown in Figure 2 is made of AHP-10V material, 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 design specifications.

Figure 2: Parts to be Processed
Figure 2: Parts to be Processed

These examples highlight the complexity of machining modern aerospace materials and the importance of selecting the right tools, parameters, and equipment to achieve the desired quality and efficiency.

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