For more than 10 years, domestic aero-engine manufacturers have introduced a large number of advanced technologies and process equipment through model technical transformation and subcontract production. With the continuous advancement of aviation materials science, new aviation difficult-to-machine materials continue to emerge and material properties continue to improve, and machining becomes more and more difficult. In the past, these advanced manufacturing techniques were not fully utilized due to the lack of efficient application of high-performance and high-performance cutting tools.
In order to improve the production efficiency of aero-dynamic mechanical cutting, promote the overall manufacturing technology of aero-engines and enhance market competitiveness, in recent years, domestic aero-engine manufacturers have attached great importance to the promotion and application of advanced cutting tools, and gradually recognized the indexable Tools and high-performance, high-performance cutting tools have significant advantages over traditional tools. It is imperative to promote indexable tools and high-efficiency and high-performance cutting tools. It is an effective way to solve the breakthrough and long-term development of aviation engine production efficiency from semi-stagnation.
Demand and development trend of aero-engine cutting technology
1 Technical requirements
(1) The main structural components such as blades, disc shafts and casings of advanced aero-engines, and a large number of new ultra-high-strength high-temperature resistant alloys, single crystal alloys, intermetallic compounds and lightweight high-strength composite materials, which add more to mechanical cutting. The great difficulty puts higher demands on the cutting technology.
(2) The low-cost manufacturing goal of aero-engines poses severe challenges to high engine development costs and long cycle times. The contradiction between cutting efficiency and cutting tool use cost has always affected the development cost and progress of aero-engines. This presents a new research topic for economical cutting technology.
(3) Advanced aeroengine growth reliability design technology, which puts forward new technical requirements for the surface integrity of key parts.
2 Development trend
(1) As a necessary supporting equipment for CNC machine tools, metal cutting tools have entered the development stage of “CNC tools†driven by CNC machining technology, showing “three high and one special†(ie high efficiency, high precision) , high reliability and specialization). The key to highly numerical and efficient cutting technology is the rational application of a series of efficient tool materials and the technical problems of corresponding practical cutting parameters optimization.
(2) New cutting processes such as dry cutting and hard cutting, represented by high-speed cutting, have shown many advantages and strong vitality, and have become the main way to improve processing efficiency and quality and reduce costs in aero-engine manufacturing technology. The main contradiction in the machining of aerospace hard-to-machine materials has shifted from being able to cut machining to high efficiency and low cost.
(3) The development of each new product of aero-engines means major changes in the function, structure and materials of the parts, and also proposes various new development tasks for the cutting process.
Current status and gap of domestic aero-engine cutting tools
1 Status
(1) The cold-processing equipment meets the requirements of the third-generation machine batch production. In particular, the equipment of some production lines has been basically the same as that selected by the foreign advanced enterprise engine production line. It can fully meet the requirements of the third-generation machine and the fourth in terms of technology and production capacity. For the development of the machine. Basically mastered the cutting processing characteristics of difficult parts of aviation parts, the machining process of special structural parts and special processing technology.
(2) In the promotion of high-performance indexable tools, new tool development, vibration cutting, new aviation difficult machining materials cutting technology research has achieved certain results, and actively adapt to the development requirements of advanced aero engines.
(3) The purchase volume of advanced tools is increasing year by year, with an average annual growth rate of 18%. For example, the total amount of purchased tools in an aviation engine factory in 2003 was only 3.8 million yuan, and by 2008, the total amount of purchased tools exceeded 100 million yuan. The main reason is that the number of model tasks is increasing, resulting in an increase in the amount of machining. At the same time, as the number of numerical control equipment increases, the number of purchased tool purchases is also increasing year by year. However, compared with the online copyright of China Metal Processing , the ratio of purchased tools to total output has not increased significantly, fluctuating between 2% and 3%. According to the ratio of the purchase cost of various tools to the total purchase cost, the tool consumption quota is: 43% for milling cutter, 27% for turning tool, 13% for drill bit (including reamer, reaming drill), 7% for boring tool, thread cutter 4%, gear cutter 3%, other tools 3%.
In recent years, the purchase of tools is mainly based on imported tools, the purchase of domestically produced tools is always at a low level, and the localization rate of tools is generally decreasing year by year. The main reason is that the quality level of domestically produced tools and imported tools is quite different, and the quality of domestically produced high-end products is not stable enough; many key parts, important parts and other difficult-to-machine materials are only available in China Metal Processing Online to have imported tools to meet the processing quality requirements; In some cases, the cost of domestically produced tools is lower than that of imported tools. In addition, due to limited test conditions, system tests cannot be performed to verify tool performance.
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