With the continuous advancement in aero-engine design, the precision and complexity of engine components have significantly increased. These parts are now lighter in weight while maintaining high performance, which brings new challenges in manufacturing. The use of difficult-to-machine materials has become more common, leading to severe work hardening, thermal deformation, and difficulties in achieving the required surface quality and dimensional accuracy. Especially when processing thin-walled parts with wall thicknesses of 2 mm or less and complex surfaces featuring deep (oblique) grooves, controlling deformation and avoiding tool chatter during CNC machining is crucial for successful production. These challenges make this type of machining a key area for technological development.
**1. Typical Characteristics of Thin-Wall Oblique Deep Groove Machining**
High-temperature alloy integral annular thin-walled parts are known for their excellent high-temperature strength and resistance to stress and corrosion. However, because these parts are made from superalloys, they are considered extremely difficult to machine due to their poor machinability and significant work hardening. As a result, such parts combine the challenges of thin-walled structures with those of hard-to-process materials. To prevent deformation and ensure dimensional accuracy, it is essential to carefully plan the process route, choose appropriate machining methods, select suitable equipment, design efficient fixtures, pick the right tools, and optimize cutting parameters.
As shown in Figures 1 and 2, these typical thin-walled parts are conical in shape, have a complex structure, and feature large radii of curvature. They are profiled thin-walled components with multiple related processes. The part has a maximum outer diameter of 600 mm, a minimum inner diameter of 500 mm, and a height of 80 mm, with a minimum wall thickness of just 1 mm. It includes six ring grooves, each 7 mm deep and 2 mm wide, with different inclination angles. The blank is a free-forged part, which involves a large amount of material removal and can generate significant internal stresses during machining, leading to deformation. Due to the narrow and deep nature of the grooves, machining these parts is highly challenging, especially on CNC machines, where the risk of tool breakage and part rejection is high.
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