As the performance of aircraft continues to increase, the requirements for aircraft parts are becoming stricter. Under the premise of meeting strength and rigidity, aviation parts should be designed to reduce weight and reduce assembly as much as possible. Therefore, modern aviation parts have several typical characteristics: complex structure, large and thin-walled parts, mostly aluminum alloy, titanium alloy, extremely strict quality requirements, small batch size, and many varieties.
The characteristics of the aerospace parts themselves determine the method of processing. Structural parts with a simple shape can also be machined using a three- or four-axis machine. However, due to the relative position of the tool and the part, it may take several times to complete the part processing. For each additional clamping, a source of error is added, which affects the accuracy of the final part and increases processing time.
Similarly, due to the relative position of the tool and the part, the programmer must be extremely careful to avoid interference between the tool and the part, and it is often difficult to use the optimum cutting position of the tool, and the cutting efficiency is extremely low.
Structural parts with complex shapes cannot be machined with a three- or four-axis machine. The five-axis linkage processing method, because of the two rotating shafts, the relative position of the tool and the parts is greatly flexible, and the whole processing of the parts under one clamping condition can be realized. The tool is able to approach the cutting surface at an ideal angle for optimum cutting conditions. Five-axis linkage machining technology is the trend of modern aviation parts manufacturing.
Five-axis linkage control techniques, such as interpolation algorithms and coordinate transformations, have developed very maturely. The technical difficulty of the five-axis machining center is still in its structural design. Although theoretically speaking, all machine tools with five-axis linkage function can process structural parts, blades, impellers or leaf discs, but the machining efficiency, machining accuracy and even the number of clamping times of different machine tools are quite different. The domestic mold industry now has many five-axis machining centers, but the five-axis machining center for the mold industry is not suitable for the aviation industry. A five-axis machining center suitable for aerospace manufacturing should have high static and dynamic stiffness to withstand the cutting forces during heavy cutting. Long-term tool life comes from stable, low-vibration cutting – a key factor in low-cost machining. The structure of a five-axis machining center for aerospace manufacturing should be adapted to the characteristics of the aerospace machining process.
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