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Precautions for titanium alloy machined parts during the processing
The cutting process of titanium alloys involves strong cutting forces
The cutting process of titanium alloy involves strong cutting forces, which means that the machine tool spindle requires significant driving power and has strong cutting capabilities. In the aerospace industry, the processing of titanium alloy parts mainly occurs during cavity milling. To facilitate chip removal, cooling and lubrication systems should be managed. This allows for the direct spraying of a large amount of high-pressure cooling lubricant onto the tool. This way, the tool can be cooled on one hand, and on the other hand, chips can be promptly flushed out of the processing area to prevent them from being cut multiple times, thereby extending tool life and avoiding scratches on the processed surface. To enable the machine tool to have high-power cutting capabilities, manufacturers of titanium processing parts have specifically designed the product structure and coordinate axis structure, equipping them with powerful cutting and oscillation units that possess excellent rigidity for mounting the tool spindle. Thus, the machine tool can generate the same cutting force at any angle, whether vertical, horizontal, or spatial.
The characteristics of titanium alloy include high strength and poor thermal conductivity. To achieve cutting efficiency similar to that of aluminum processing, it is necessary to increase cutting parameters as much as possible, namely increasing the feed rate and cutting depth, which leads to increased cutting forces and may result in static deviations between the workpiece and the tool, potentially causing part damage. This can lead to a decrease in shape accuracy or instability in the processing process, which also accelerates tool wear. Therefore, machine tools used for titanium alloy processing have high power and possess static and dynamic characteristics (higher static and dynamic stiffness); they also need to be equipped with corresponding high-pressure cooling and lubrication equipment for low-speed, high-torque processing. Timely cleaning of chips is essential to reduce tool wear and minimize heat generated during the processing. To enhance the rigidity of the machine tool, some manufacturers use welded steel structures in box-type or closed-frame designs. High-power feed motors and high-rigidity, backlash-free guiding systems can be fixed in the processing position to further improve the machine's rigidity. Additionally, improvements include the entire system of the spindle tool connecting rod and tool holder, enhancing rigidity during the processing.
In addition to static stiffness, the dynamic characteristics of the machine tool also play a decisive role in the effective processing of titanium alloys. Controlling the stability of the process is a significant challenge. If the machine tool has low rigidity and poor damping characteristics, high cutting forces during the cutting process may induce self-excited vibrations, especially at low speeds and when the excitation frequency approaches the machine tool's natural frequency, leading to chatter during processing. This chatter not only affects the surface quality of the workpiece (with vibration lines) but can also damage the machine structure, tool wear, and even lead to tool breakage. The stability of the processing process mainly depends on parameters such as spindle speed and the selected cutting depth. Users should understand the performance of the machine tool and the maximum achievable cutting depth. They can also proactively place anti-vibration pads on the machine tool and pre-set parameters in the machine control equipment to avoid exceeding the limits of cutting depth. Vibration mitigation measures can further enhance the machine's seismic resistance.
Titanium alloy,Cutting,Lubricant
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