In the aerospace, automotive, and electronics industries, there is a growing demand for parts that are stronger, more rigid, tougher, and resistant to corrosion and fracture, while also being lighter. To meet these requirements, thin-walled monolithic structures made from lightweight alloys are widely used. These structures not only enhance performance but also reduce the total number of components and assembly efforts. However, the material removal rate in such parts can be as high as 90% or more, which makes it crucial to control machining distortion and improve efficiency. This has led to the adoption of advanced machining technologies, with high-speed cutting emerging as one of the most promising solutions.
High-speed cutting offers significant advantages, including higher processing efficiency, lower cutting forces, reduced surface temperatures, and improved accuracy—especially for thin-walled monolithic structures. A notable example is the use of high-speed milling in the production of fuselage components for Boeing and Airbus aircraft. This technique has allowed for thinner fins and increased height, significantly reducing the aircraft's weight and fuel consumption. As a result, long-haul flights without refueling have become possible between regions like East Asia and Western Europe.
Domestically, the application of high-speed cutting is still in its early stages. This paper focuses on the optimization of high-speed milling processes for aluminum alloy triple waveguides, which are typical examples of thin-walled, monolithic structures. The test involved a product with a minimum wall thickness of 2mm and a mass of 2.35kg, made from rust-proof aluminum LF21 (GB1173-86). The raw material was a rectangular plate weighing approximately 12.25kg, with a material removal rate of 80.8%. The challenge lay in controlling deformation during the machining process.
The experiment used a German Hermle C1200U five-axis high-speed milling machine, equipped with a Heidenhain iTNC 530 CNC system. The machine featured high spindle speeds, precision, and efficient tool management. The workpiece was modeled using UG NX software, and the tool path was generated accordingly. The clamping method involved securing the part at four points on both sides, preventing deformation and eliminating the need for special fixtures.
To minimize distortion, the process followed a layered cutting approach, ensuring symmetry and stability. High-speed cutting was applied with optimized parameters, including axial depth, radial depth, and feed per tooth. The cutting speed was set above 1,130 m/min, significantly reducing cutting forces and temperatures. The final results showed that the machining time was reduced to 14.13 hours, meeting the target and improving overall efficiency.
This study highlights the importance of optimizing various factors, including tool selection, cutting parameters, clamping methods, and cooling systems. It demonstrates that high-speed milling can effectively reduce distortion, improve accuracy, and enhance productivity when properly implemented. The integration of advanced CAD/CAM systems and high-performance machine tools is essential for achieving these benefits.
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