In the aviation manufacturing this high-end equipment ‘arena’, five-axis linkage machining technology has become a key ‘player’ to multi-axis synergistic flexible machining and micron-level precision, to overcome the aero-engine, aircraft structural components manufacturing problems, aviation equipment breakthroughs to inject manufacturing Kinetic energy.

Aero-engine as the aircraft ‘heart’, its turbine blades, magazines and other parts processing is a technical difficulty. Turbine blade surface is complex, the traditional three-axis machining requires multiple clamping, splicing tool path, blade profile error of 0.05mm, affecting the aerodynamic efficiency of the engine. Five-axis machining allows the tool to cut continuously and smoothly along the blade surface, complete the blade body and root machining in one clamping, and the profile error is controlled within 0.005mm, which improves the fuel efficiency of the engine by 5%. When processing the engine magazine, five-axis machining using rotary axis to adjust the angle of the workpiece, milling out deep holes, sloping grooves and other complex structures, instead of the traditional EDM, shortening the machining cycle by 60%, to help aero-engine to a more efficient, more compact development.

Aircraft structural parts manufacturing, five-axis machining is also indispensable. Aircraft wing beams using high-strength titanium alloy, traditional processing due to tool interference, it is difficult to mill complex skeleton structure, five-axis linkage machining by virtue of the double pendulum head, double rotary table structure, the tool around the workpiece multi-angle cutting, can be milled out of the skeleton beams to reduce the weight by 30%, not only to reduce the weight of the aircraft, but also to protect the structural strength. When processing the aircraft hatch frame, it can mill the shape and turn the connection holes at the same time, so that the frame flatness error is ≤0.01mm, which improves the sealing and reliability of the aircraft hatch and ensures flight safety.

The technology is adapted to the needs of aviation, and the five-axis linkage machining is constantly evolving. For the difficult machining of aviation titanium alloy and composite materials, the equipment is equipped with a high-pressure cooling system, cutting fluid pressure of 100bar, flushing away the high temperature in the cutting zone, extending the tool life by 3 times, and increasing the cutting speed from 50m/min to 150m/min when machining titanium alloy. The intelligent machining system integrates the aviation parts process database, importing the blade model to automatically match the optimal cutting parameters, eliminating the need for repeated debugging by the operator, and achieving a machining consistency of 98 per cent, guaranteeing the interchangeability of each engine part.

However, the aviation field of five-axis linkage machining requirements are stringent, the equipment needs to be certified by the GJB (National Military Standard), technical personnel need to master the aviation process, precision machining and other areas of knowledge, the industry has a high barrier to entry. However, with the development of the aviation industry, more and more companies are investing in research and development, the localisation rate of equipment has increased from 20% to 40%, and the training of talents has been incorporated into the practical courses of aviation colleges and universities. In the future, five-axis linkage machining will be integrated with digital twin technology, virtual simulation of aviation parts machining process, optimise the tool path in advance, risk avoidance, so that the aviation manufacturing is more intelligent and reliable, and continue to escort the breakthrough of high-end aviation equipment.

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Integration and Upgrade of Turning & Milling Machining Drive Leap in Manufacturing Efficiency

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Integration and Upgrade of Turning & Milling Machining Drive Leap in Manufacturing Efficiency

Transforming High-End Manufacturing: Innovations in Specialized Casting Techniques

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