Aerospace manufacturing industry is in the advanced field of high-performance processing technology, the performance and precision of mechanical parts, especially in high temperature, high pressure and other harsh conditions used mechanical parts. The manufacturing of these components relies on accurate and reliable high performance machining techniques such as high speed machining, multi-axis machining, micro-machining and typical aerospace materials processing. These technologies not only improve production efficiency and reduce costs, but also ensure the quality and performance of parts .

In the field of aeronautics and Astronautics, the heavy parts such as impeller, blade, casing and thin-wall parts are usually made of high-performance alloy, whose design is complex and precision is required very high. In addition, these components in processing deformation, especially thin-walled parts, so high-performance processing technology in the manufacture of these critical parts is very important. These technologies not only deal with difficult-to-process materials, but also ensure product quality and performance in extreme operating environments and complex design requirements, while achieving micro-to nano-scale processing accuracy , particularly in the production of impellers, blades and casings and other critical components, showing significant advantages.

In summary, the application of HPM in aerospace industry not only improves manufacturing efficiency and product quality, but also promotes the development of new materials and innovative design. This is critical to meeting the stringent standards and complex manufacturing requirements of the aerospace manufacturing industry.

The connotation of high-performance technology processing

High performance machining (HPM) is a kind of engineering technology, which combines the key elements of HSM, multi-axis machining, micro-machining and difficult-to-machine material technology, designed to improve material processing efficiency, accuracy and performance, the framework is shown in Figure 1. In the aerospace field, these technologies are used to manufacture high-demand components to meet the complexity and reliability requirements, and promote the continuous progress of manufacturing technologies in this field.

Fig. 1 high performance machining technology framework

high speed machining technology

High-speed machining technology in aerospace field plays a key role in the production of precision and complex parts. By improving material removal rate and optimizing machining path, the production cycle is shortened and the surface quality of parts is improved. In high-speed milling, solid and indexable ball-end milling cutters are used to process complex structures on convex and concave surfaces and five-axis CNC milling machines, as shown in Figure 2, which shows the diversity and complexity of the technology.

A) milling convex surfaces b) milling concave surfaces

C) milling complex structure
Fig. 2 milling process under different conditions 

By optimizing the milling parameters of PCD tools, the machining efficiency and surface quality of TC4 titanium alloy were improved significantly. Luis et al.found that in complex surface milling, maximum radial depth, feed and down-cutting strategies are critical to improve surface quality and productivity. Vogel et al. developed an advanced tool shank with an internal particle-filled structure that was tested in turning at Monfort, as shown in Figure 3, by reducing vibration during titanium alloy processing, increased machining efficiency and tool life.

A) test setup

B) shank structure
Fig. 3 the test setting of the padded shank and the shank structure

In addition, the application of advanced CAM systems, such as MASTERCAM, UNIGRAPHIC snxhe CATIA, provides a variety of tool path strategies for machining . Hascoet and Rauch use OpenNC controller and NURBS tool path interpolation, further improve the quality and efficiency of high-speed machining, for aerospace manufacturing industry has brought significant progress.

multi-axis machining technology

In the aerospace industry, multi-axis machining technology, especially the application of four-axis and five-axis CNC machine tools, has significantly improved the production efficiency and quality of key parts, bringing significant innovation.

In specific application research, FAN et al. 10 developed a five-axis machining method specifically for centrifugal impellers, which divides the impellers into different regions, tool paths are optimized to achieve accurate and efficient milling. Mhamdi et al. 11 developed a dynamic model for multi-axis milling of aero-engine blades Ti-6Al-4V, achieving better accuracy and surface quality in blade manufacturing and addressing complex shape and material challenges. Chen Kaihang developed a semi-real-time speed planning method for five-axis NC machining of impellers, which effectively improves the machining quality and efficiency and meets the actual engineering needs. Taking the semi-open integral impeller as an example, the multi-axis machining site and sample are shown in Figure 4.

A) finish machining process of impeller

B) semi-open integral impeller
Fig. 4 multi-axis machining site and sample

In addition, Wenhao et al. developed a new method to generate tool axis vector for mesh surface machining to improve the efficiency and accuracy of multi-axis CNC machining. Wang Bo et al.  developed a method for modeling the trace of cutting edge micro-elements in multi-axis ball-end milling. They constructed a dynamic model integrating tool geometry features to accurately predict milling forces.
The application of multi-axis machining technology in aerospace field is more and more extensive, and the improvement of production efficiency and manufacturing quality can not be ignored. The development and application of this technology open up a new way for further innovation of aerospace manufacturing industry in the future.

microfabrication

In the aerospace field, micro-machining technology, especially micro-milling, micro-discharge machining, laser micro-machining and ultrasonic machining, plays a crucial role. These technologies play a key role in manufacturing micro-components with complex shapes and high precision requirements.

Micro-milling technology has shown advantages in manufacturing micro-components with high precision and complex geometry. Tian Lu et al.  ade progress in the optimization of minimum cutting thickness and cutting force, while Li et al.  developed a new micro-nano composite ceramic tool material Ti (C, N)/WC/ZRO2 for micro-milling cutters, the bending strength, toughness and hardness of the cutting tool are effectively increased. In addition, Zhang Xinxin et al. optimized the high-speed micro-milling cutting parameters for tough materials such as titanium alloy and stainless steel, improving the surface quality and machining efficiency of these difficult-to-machine materials.

In the field of micro-electro-discharge machining (EDM) , Tagawa has demonstrated the effectiveness of EDM in improving the machining efficiency and surface quality of Ti-6Al-4V titanium alloy. Lin et al.  optimized the micro-milling electrical discharge machining of Inconel 718 by Taguchi method to achieve the balance between electrode wear, material removal rate and working clearance, thus improving the machining efficiency. Huu et al.  improved the processing efficiency of titanium alloys by using carbon-coated electrodes, demonstrating the potential of non-contact machining in hard materials. Garzon et al. 21 focused on force measurement techniques in micro-electrical discharge machining, providing more accurate monitoring of the machining process. The combined machining platform constructed and optimized by this device on a Sarix SX200 machine tool is shown in Figure 5.

Fig. 5 combination machine tool: micro-milling + micro-electrical discharge machining

The development of laser micromachining technology has significantly improved the local processing performance of many materials, as shown by Chavoshi's study, by high-energy laser beam local processing of a variety of materials to improve processing performance. Xiao Qiang et al.  have successfully fabricated micro-and nano-structures using femtosecond laser processing. Sun et al. used μct to detect cavity defects in Ti-6Al-4V manufactured by laser lamination, providing important information for aerospace quality assurance.

At the same time, ultrasonic machining technology has also made important progress. The high-speed ultrasonic wave cutting technology developed by Peng Zhenlong et al.  improves the cutting speed and efficiency of difficult-to-cut materials, while Zhao et al. 26 utilize the self-developed RUVAG device based on workpiece vibration, the experiment of single CBN grain grinding was carried out to reveal the material removal mechanism and wear performance of CBN grain by radial ultrasonic vibration. The ultrasonic-assisted drilling (UPD) method proposed by Liu et al.  effectively improves the drilling efficiency and quality of CFRP/Ti laminates.

The comprehensive application of micro-machining technology not only shows their unique advantages, but also shows great potential in the manufacturing of micro-parts with high precision and complex design. With the continuous development of micro-cutting technology, it will continue to promote aerospace and other precision manufacturing industry progress.

typical aviation disaster machining materials

In the aerospace industry, it is very important to study the precision machining technology of titanium alloy, aluminum alloy and carbon fiber composites. Because of their excellent mechanical strength and corrosion resistance, these materials play an important role in the manufacturing of aviation heavy-duty components, but they also bring processing challenges.

In the field of titanium alloy processing, Tian Rongxin et al put forward a method of optimizing process parameters for high speed milling of TC11 titanium alloy. Liu Peng et al.  developed a mathematical model to optimize the cutting force in high-speed milling of Ta15 titanium alloy with PCD tools, and verified its effectiveness. Hourmand et al.  found that coated tungsten carbide (WC or WC/CO) tools perform better in terms of wear, smoothness, life and friction than uncoated tools. Ezugwu et al. have found that high-pressure cutting fluid can significantly improve surface smoothness and tool life and reduce physical damage in high-speed precision turning of TC4 with PCD tools. In addition, Yao Jun et al  effectively increased the machining efficiency and reduced the cost of TB6 titanium alloy by applying the vibration electrochemical cutting technology.

In aluminum alloy machining, Dong et al  focused on the wear of diamond tools in precision machining, highlighting the impact of tool clearance and feed speed. Wang et al research on the machining of 7050-T7451 aluminum alloy shows that larger front angles and thicker chips can significantly reduce energy consumption, thus achieving more efficient and environmentally friendly manufacturing. In addition, Jarosz et al.  significantly reduced the processing time (about 37%) of AL-6061-T6 aluminum alloy by optimizing the CNC milling parameters, thus improving the processing efficiency.

In addition, for aerospace carbon fiber material processing, Wu et al. 36 developed polycrystalline diamond cutting tools for carbon fiber reinforced plastics (CFRP) , improving cutting efficiency and quality. The stochastic model developed by Zhang et al. can accurately predict the cutting force of milling fiber reinforced composites, which is of great significance for improving the machining accuracy and efficiency of composites. Wu et al.  used the finite element model and the Deform 3D software to carry on the simulation analysis, has solved the drilling problem, has improved the processing quality.

To sum up, in the aerospace field, the machining technology of typical difficult-to-machined materials is the key to realize the manufacturing of high-performance aerospace key parts. The development of these cutting techniques not only improves the machining efficiency and precision, but also opens up new possibilities for cutting, machining and forming of other difficult-to-machine materials.