Application of digital mold manufacturing technology in aerospace field

Liu Wenyi, Xi’an Aviation Power Control Company

In recent years, with increasing national emphasis on the development of the mold industry and talent cultivation, mold technology in the aerospace sector has also seen significant progress. Aerospace products are becoming more diverse and high-performance oriented, which requires mold manufacturing units to deliver high-precision molds quickly for the development and commissioning of production systems. To meet these demands, the company has fully integrated digital technologies such as CNC machining and computer-aided manufacturing (CAM) into every stage of mold production—ranging from design, processing, simulation, to data collection. This approach enables rapid prototyping and high-speed machining, ensuring timely completion of product tasks.

Milling of Thin-Walled Parts

CNC milling of thin-walled components is a common practice in mold manufacturing. By analyzing the NC machining process of a thin plate bracket using UG software, we have identified patterns of deformation during thin-wall milling and proposed compensation methods to address it. Thin-walled parts typically consist of side walls and webs, which are structurally simple but have large machining allowances and low rigidity. As a result, they are highly susceptible to deformation caused by cutting forces, heat, and vibrations, making it challenging to maintain precision and efficiency. This issue becomes a major bottleneck in the production of thin-walled mold parts. The part in question is a thin plate bracket made of forged aluminum alloy LD5, known for its complex structure and typical thin-wall characteristics suitable for CNC milling.

Thin Wall Parts

The machining contour consists of curved arcs and straight lines, with a geometric tolerance of IT14 and a surface roughness of Ra=6.3 mm. During machining, vibration is likely to occur, affecting wall thickness tolerance and surface finish. The blanks have a minimum machining allowance of 5 mm across all areas, leading to significant size changes during processing. Due to poor rigidity, large deformation errors can occur before and after milling. Therefore, selecting the right cutting tool materials is crucial—preferably those with chemical vapor deposition coatings that offer excellent wear resistance, impact strength, and hardness. Additionally, the tool holder must meet strict requirements for dynamic balance, geometric accuracy, and clamping stability. A 1:10 HSK vacuum tool holder is used, along with a two-hole positioning system and a special vacuum platform to ensure secure clamping and minimize vibration, especially for thin plates. To address deformation issues during thin-wall milling, traditional methods often involve multiple passes without feed after finishing, which reduces efficiency. In this case, an active tool path optimization method was applied. Using finite element analysis, the deformation amount was calculated and imported into UG software to create a compensated NC program. This allows the tool path to be adjusted based on deformation data, effectively reducing residual material and ensuring accurate wall thickness in one pass. While this approach improves efficiency, the complexity of thin-wall machining means further research is needed to fully understand and control all influencing factors.

CNC Electric Discharge Machining

CNC EDM technology plays a vital role in mold manufacturing, especially for complex shapes and difficult-to-machine materials. Before mold production, the appropriate process is selected based on the component's characteristics and requirements. To reduce time, cost, and improve efficiency, processes like milling and wire cutting are commonly used. However, when these methods are not feasible or the workpiece has special needs—such as deep cavities, small features, or high-hardness materials—EDM becomes essential. A fast clamping positioning system is an advanced method for electrode manufacturing. Electrodes are clamped directly on the machine tool’s system, allowing them to be mounted immediately on the EDM machine, greatly improving efficiency and ensuring accurate positioning. Electrode design and manufacturing start with CAD/CAM software. The company uses UG and MasterCAM to create 2D electrodes, ideal for cleaning corners or producing full electrodes. Wire-cutting is particularly effective for sheet-like electrodes, offering high efficiency and precision. With slow wire-cutting machines, even complex sloped or multi-profile electrodes can be machined accurately. Choosing the right electrical parameters in EDM directly affects processing outcomes. Parameters are selected based on electrode count, loss, working fluid, surface finish, and other factors. Roughing parameters focus on electrode scaling, while finishing parameters prioritize surface quality. Modern CNC EDM machines come with pre-set optimal parameters, and automated selection simplifies the process.

Application of Mold Manufacturing Technology in Aerospace

With the growth of the aerospace industry, digital technologies have been increasingly adopted in mold manufacturing, leading to rapid advancements. These innovations have enabled companies to enter international markets, although the depth of digital adoption still needs improvement. Despite progress, the mold industry, especially in complex and high-precision areas, lags behind many Western countries. To bridge this gap, continued investment in digital manufacturing technologies is essential. By integrating these technologies, the traditional mold industry can evolve, enhancing both productivity and quality.

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