There are many types of aviation materials, mainly divided into metal materials and non-metallic materials, common metal materials are structural steel, stainless steel, high temperature alloys, metal alloys, common non-metallic materials are adhesives, insulating materials, lubricating materials, Plastic and so on. With the development of aviation industry, the processing of product materials put forward higher requirements. In order to improve the processing quality, you need to clear the characteristics of different tool materials, use the right processing tool. This article will help you choose the right cutting tools materials specific for different common materials.
Tool material selection requirements
In the selection of the tool material, we need to clearly determine several elements of the product
(1) Processing efficiency of the product
(2) Cutting speed of the product
(3) Feed speed
(4) The removal rate of the material
In the actual processing, if only to improve the cutting speed of the material, it will lead to heat rise, the product processing efficiency will be affected by the thermal conditions and thermal conductivity of the material. Therefore, in the selection of materials at the same time, we need to take full account of the environmental effects, and choose the materials with good red hardness and the dry cutting method, For example, it will affect more on the ceramic, metal, BN and other materials.
Combined with the actual processing, when the cutting temperature reaches 700~800℃, the diamond tool surface will appear a slight carbonation problem, so in the process of dry cutting, it must also strictly control the temperature. Therefore, in the selection of aviation materials processing tool, we need to focus on the chemical effect between the product materials and tool material. For example, in the processing of magnesium aluminum and other metals, we should choose diamond tools or cbn insert.
In the process of roughing and chip breaking, it is necessary to ensure that the toughness of the tool material satisfies the processing requirements. When finishing, the tool material with low toughness is used. Normally, the fracture toughness and impact toughness are high. With high reliability, low toughness of the tool material reliability is also low.
Selection of Tool Materials in Aeronautical Materials Processing
1 Aluminum alloy
In the process of selection of aluminum alloy processing, we need to focus on the chemical properties of aluminum materials, aluminum materials and a variety of tool materials will occur chemical reaction, but no chemical reaction with carbon, so we general use of diamond tools for aluminum alloy Processing.
2 Steel
General steel products processing, cutting speed will be higher than 350 m/min, this process will be called high-speed processing, but we must pay attention on the cutting speed of the tool material.
(1) If the cutting speed below 510 ~ 2000m/min in the process, you can use ceramic cutters and coating tools.
(2) If the cutting speed at 750 m/min, you can use Si3N4 ceramic cutting tools;
(3) If the cutting speed at 2000 ~ 4500 m/min, you can use CBN Insert, such as BN-H21 for interrupt turning and BN-H10 for fine finishing.
Specific for high hardness steel parts, we should choose CBN Insert Materials in the high speed process. And the cbn tool materials can be used for machining alloy steel materials, HMS and Hi Chrome Cast Iron parts. CBN Insert is the ideal cutting tools to improve the processing efficiency on machining HMS, the cutting efficiency and the economic benefit will higher than coating carbide insert and the Si3N4 materials tools.
3 High temperature alloy
In the process of processing superalloy materials, we generally use high-performance high-speed steel materials, silicon nitride ceramics and alumina ceramic cutting tools, and can achieve intermittent turning. In the process of processing nickel-based superalloy, you can use enhanced Al2O3 ceramic cutting tool, the processing temperature can reach 950℃. Compared with the carbide cutter, the material removal rate is high, it can process the complex parts of the engine turbine.
4 Titanium alloy
In the process of machining titanium alloy materials, we commonly used in high-speed steel planer and cutter. As the titanium metal has a strong chemical activity, in the processing process can’t be applied ceramic tool. In the role of high pressure coolant, we use polycrystalline diamond tool for titanium alloy finishing, the product can be controlled within the roughness of 1.6 μm or less. In addition, the process must focus on the useful life of the tool to avoid the react between the tool material and product materials.
5 Metal matrix composites
Aluminum-containing silicon nitride material is a common metal-based composite material, in the process of processing such materials, you can use cbn materials and polycrystalline diamond tool. In the process, silicon nitride particles gradually rupture, processing materials can be used artificial polycrystalline diamond tool, it is worth noting that the application of carbide tools sometimes leave the remaining material on the surface of the feed traces, but the surface bright Neat, the surface roughness of the material can be controlled below 0.8 μm. Application of artificial clustering Crystal diamond tool processing, the material surface contour is very clear, you can control the surface roughness of the material below 0.4 μm.
6 Fiber Reinforced Composites
Fiber-reinforced composites (such as glass fiber composites and carbon fiber composites) contain a certain amount of reinforcing material, which can be difficult to achieve in actual machining. Generally, carbide cutting tools and ceramic materials are used, but the tool life Shorter. So superhard material tool become the ideal tool for processing fiber reinforced composite materials, superhard material tool life is longer, can be widely used in the finishing of materials.
Concluding remarks
In the process of machining the metal materials, we need to avoid the reaction between the product materials and the cutting tool materials, and avoid the similar element between the materials, avoid the tool wear. Generally, ceramic materials and superhard materials can be made for cutting tips. Specific for the parts with complex dimension, we can choose HSS and Carbide Materials tools, we should use alloy materials with ultra fine grain as the cutting tools materials when fine finishing. Last, we need consider the both the materials costs and value the environmental benefit and control the processing costs when we choose the cutting tools materials.