Milling method of nickel-based superalloy honeycomb

Abstract

The milling method of the nickel-based high-temperature alloy honeycomb comprises the steps that S1, when the nickel-based high-temperature alloy honeycomb is roughly milled, an integral crushing milling cutter is adopted, allowance is reserved, at least six rows of first chip grooves which are spirally and gradually increased anticlockwise in the axial direction are formed in the circumferential direction of the crushing milling cutter, and when the first chip grooves are used for machining the thickness of a part, the chip removal resistance can be reduced; s2, an integral hard alloy milling cutter is adopted during finish milling of the nickel-based superalloy honeycombs, double-edge large-angle spiral progressive second chip grooves are formed in the circumference of the hard alloy milling cutter, and the second chip grooves can split and crush the intermittent honeycombs during milling, so that the milling resistance is reduced, and the milling efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the technical field of aero-engine manufacturing processes, and particularly relates to a milling method for nickel-based high-temperature alloy honeycomb. Background Technology

[0002] Currently, the processing methods for nickel-based superalloy honeycomb are electrical discharge machining (EDM) or grinding. EDM requires enterprises or units to configure corresponding EDM equipment, resulting in high investment costs. It is also greatly affected by the EDM capacity, and a remelted layer (micro-cracks) exists on the honeycomb surface after processing. Grinding is inefficient and cannot meet the requirements of mass production of parts. It also has high requirements for grinding wheels and grinding parameters. If the grinding wheel is not ground in time, internal burrs are easily generated, causing parts to be scrapped and reducing processing efficiency.

[0003] In view of this, the present invention is hereby proposed. Summary of the Invention

[0004] The purpose of this invention is to provide a milling method for nickel-based superalloy honeycomb, solving the technical problem of low processing efficiency in traditional methods. The technical solution of this invention has many beneficial effects, as described below:

[0005] A milling method for nickel-based superalloy honeycomb, the milling method comprising,

[0006] S1: When rough milling nickel-based high-temperature alloy honeycomb, an integral crushing milling cutter is used with a margin. The crushing milling cutter is provided with at least 6 rows of first chip removal grooves that spirally advance counterclockwise around the axial direction. The first chip removal grooves can reduce the resistance to chip removal when dealing with both coarse and fine parts.

[0007] S2: When precision milling nickel-based high-temperature alloy honeycomb, an integral carbide end mill is used. The carbide end mill has a double-edged, large-angle spiral progressive second chip groove in the circumferential direction. The second chip groove can split and break the discontinuous honeycomb during milling, thereby reducing the milling resistance.

[0008] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects:

[0009] The method of this invention is not limited to processing sites or machine tools, and has strong applicability. It can be used universally in the machining industry to process nickel-based superalloy honeycomb. It can be installed on machining centers, milling machines and other equipment. As long as the processing parameters are set correctly, it can achieve milling of nickel-based superalloys. Moreover, it has high processing efficiency and stable quality. It uses a break milling cutter to quickly remove large excess material, and then uses a sharp carbide milling cutter to correct the honeycomb size, suppressing and removing the fine burrs generated during the milling process. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] Figure 1 Image of a solid-state crusher milling cutter

[0012] Figure 2 This is a structural diagram of a monolithic breaker milling cutter;

[0013] Figure 3 This is a structural diagram of a carbide end mill. Detailed Implementation

[0014] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0015] Furthermore, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that aspects can be practiced without these specific details. To enable those skilled in the art to better understand the invention, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined as "first" and "second" may explicitly or implicitly include one or more of that feature. In the description of the invention, unless otherwise stated, "a plurality of" means two or more.

[0016] Currently, the industry commonly uses electrical discharge machining (EDM) and grinding wheel grinding to process nickel-based superalloy honeycomb. However, EDM suffers from high efficiency and a large heat-affected zone, while grinding wheel grinding suffers from unstable accuracy. Therefore, improved methods are needed. Through innovative tool structure design, process step division, and parameter synergistic optimization, the industry problems of low efficiency and poor quality in nickel-based superalloy honeycomb processing have been solved. Figure 1 The milling method for nickel-based superalloy honeycomb shown improves the processing quality and efficiency of nickel-based superalloy honeycomb, eliminating problems such as edge sagging, breakage, and burr inward turning. The milling method includes...

[0017] S1: For rough milling of nickel-based superalloy honeycomb, an integral chip breaker is used, with a allowance for material removal. The chip breaker has at least six rows of counter-clockwise spiral chip grooves circumferentially, typically eight. These first chip grooves reduce chip removal resistance when milling the part, breaking up discontinuous honeycomb layers during milling. This results in low milling resistance, minimal or no honeycomb deformation, and thus allows for the removal of a large amount of honeycomb material. Specifically…

[0018] like Figure 2 As shown, after rough milling with the breaker end mill, a margin of 0.1 to 0.15 mm is left. For this margin, a carbide end mill is used for finish milling. Preferably, the spiral angle of the first chip groove is 70°-75°, the spiral groove depth is 1.2 mm to 1.5 mm, and the cutting length is adapted to the length of the honeycomb being cut. Furthermore, the multiple first chip grooves intersect each other in the spiral direction and on the outer circumference of the cutting edge, forming a pineapple shape with short and dense cutting tips.

[0019] Furthermore, the diameter of the breaker milling cutter is Φ10. Rough milling stage: An integral breaker milling cutter is used, which has at least 6 rows of counterclockwise spiral progressive chip removal grooves in its circumference. Through the spiral angle (70°-75°), groove depth (1.2-1.5mm) and cutting edge cross design, the chip removal resistance can be significantly reduced, achieving efficient removal of large honeycomb material, while reducing deformation.

[0020] S2: As Figure 3As shown, a solid carbide end mill is used for finish milling of nickel-based high-temperature alloy honeycomb. The carbide end mill has a double-edged, large-angle spiral progressive second chip flute in the circumferential direction. The second chip flute can break up and split the discontinuous honeycomb during milling, thereby reducing milling resistance. Specifically, the depth of cut for finish milling honeycomb with the carbide end mill is 0.05mm-0.1mm. Finish milling is performed to accommodate the above-mentioned allowance. Generally, the linear speed is set at 20m / min to 25m / min and the rotational speed is set at 800r / min. The diameter of the carbide end mill is Φ10. In the finish milling stage: a solid carbide end mill is used, employing a double-edged, large-angle spiral chip removal groove to break up and disperse intermittent honeycomb, further reducing resistance, accurately correcting dimensions, and suppressing burrs. The rough milling parameters—depth of cut (0.3-0.5mm), linear speed (210-240m / min), spindle speed (7000r / min), and allowance (0.1-0.15mm)—form the foundation for and coordinate with the finish milling parameters. In finish milling, the depth of cut (0.05-0.1mm), linear speed (20-25m / min), spindle speed (800r / min), and tool diameter (Φ10) are combined to balance cutting efficiency and machining accuracy, avoiding problems such as honeycomb edge collapse and burrs. For example, high spindle speed combined with high linear speed in rough milling quickly removes the allowance, while low linear speed and small allowance in finish milling ensure surface quality.

[0021] The method of this invention is based on the combination of an improved break milling cutter and a carbide milling cutter, and an overall solution for machining centers with optimized process parameters. It achieves a dual improvement in efficiency and quality. Compared with electrical discharge machining and grinding, this method improves machining efficiency by more than 30% through milling processes (such as high-speed rough milling to remove excess material and rapid dimensional correction in finish milling). It also produces a surface free of remelted layers and burrs, ensuring stable quality and reducing scrap rate. Furthermore, this method has no special requirements for machine tools and can be adapted to general equipment such as machining centers and milling machines, significantly reducing enterprise equipment investment costs. At the same time, it can extend tool life (carbide milling cutters have high wear resistance), saving machining costs. The novel milling method for honeycomb structures exhibits significant advantages: by combining a break milling cutter and a carbide tool with dynamic cutting parameters, material removal is increased by more than four times, and the single-piece machining cycle is shortened by 50%-75%. Furthermore, through the synergistic optimization of tool geometry parameters and cutting paths, the vertical error of the honeycomb structure sidewalls is reduced to <0.01mm, the surface roughness Ra value is stabilized at 1.6μm, and there are no internal burrs on the honeycomb surface. Moreover, by using carbide-coated tools with optimized machining parameters, the tool life is extended to 5-8 times that of grinding wheels, machining efficiency is increased by more than 50%, and overall machining costs are reduced by more than 35%. Particularly noteworthy is that the milling honeycomb scheme effectively avoids the problems of thermal damage from electrical discharge machining and stress concentration from grinding. This technological breakthrough provides a more efficient, precise, and economical machining solution for the manufacture of honeycomb components for aero-engines, and has significant engineering application value.

[0022] The product provided by this invention has been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the embodiments above are merely for the purpose of helping to understand the core ideas of this invention. It should be noted that those skilled in the art can make various improvements and modifications to the invention without departing from the principles of the invention, and these improvements and modifications also fall within the protection scope of the invention claims.

Claims

1. A milling method for nickel-based superalloy honeycomb, characterized in that, The milling method includes, S1: When rough milling nickel-based high-temperature alloy honeycomb, an integral crushing milling cutter is used with a margin. The crushing milling cutter is provided with at least 6 rows of first chip removal grooves that spirally advance counterclockwise around the axial direction. The first chip removal grooves can reduce the resistance to chip removal when dealing with both coarse and fine parts. S2: When precision milling nickel-based high-temperature alloy honeycomb, an integral carbide end mill is used. The carbide end mill has a double-edged, large-angle spiral progressive second chip groove in the circumferential direction. The second chip groove can split and break the discontinuous honeycomb during milling, thereby reducing the milling resistance.

2. The milling method according to claim 1, characterized in that, The depth of cut of the crusher in S1 when rough milling the honeycomb is 0.3mm-0.5mm, the linear speed is 210m / min-240m / min, and the rotation speed is set to 7000r / min.

3. The milling method according to claim 2, characterized in that, After rough milling with a breaker end mill, leave a margin of 0.1 to 0.15 mm, and then perform finish milling with a carbide end mill; The first chip removal groove has a spiral angle of 70°-75°, a spiral groove depth of 1.2mm-1.5mm, and a cutting length that matches the length of the honeycomb being cut. Alternatively, multiple first chip removal grooves may intersect each other in the spiral direction and on the outer circumference of the cutting edge.

4. The milling method according to claim 2, characterized in that, The diameter of the breaker milling cutter is Φ10.

5. The milling method according to claim 1, characterized in that, When the carbide end mill in S2 is used for finish milling of the honeycomb, the depth of cut is 0.05mm-0.1mm, the linear speed is set to 20m / min-25m / min, and the rotation speed is set to 800r / min.

6. The milling method according to claim 5, characterized in that, The diameter of the carbide end mill is Φ10.

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