End milling cutter in the ordnance industry processing of special materials

End milling cutter plays a key role in the processing of special materials in the weapons industry, especially in the processing of difficult materials such as titanium alloy and carbon fiber composite materials. Through tool design, parameter optimization and process innovation, efficient and precise machining is achieved. Here are the technical details and challenge solutions:

First, the core application scenario of the end mill in the weapons industry

Complex structural parts processing

In the weapons industry, end milling cutter is widely used in aircraft fuselage beam, rib, wall and other titanium alloy structural parts, as well as carbon fiber composite materials edge, surface milling. Its versatility (plane, groove, copy milling) ADAPTS to complex geometries.

High hardness material adaptation

Tungsten carbide end mill (coated TIN+TiAIN) can process titanium alloy, stainless steel and other materials, but it should be noted:

Clamping reliability: Before processing, clean the tool handle and tool holder to avoid loosening caused by oil film.

Vibration control: Reduce the impact of vibration on accuracy by adjusting the cutting parameters (such as reducing the speed by 40%) or by using an anti-vibration end mill (asymmetrical tooth structure, variable core thickness groove).

Second, special material processing technical details

1. Titanium alloy processing technology

Tool optimization

Material: ultrafine grain carbide (bending strength 600-800MPa) or PCD coated tool.

Geometric design: large spiral Angle (48°) combined with dense tooth structure, improve chip removal efficiency; 13° front Angle reduces cutting force, 8° arc back Angle reduces friction.

Parameter selection

Cutting speed: 50-110m/min (such as TC4 titanium alloy up to 200m/min).

Feed rate: each tooth feed 0.05-0.1mm/z, side cutting capacity ≤0.1D.

Cooling method: high pressure internal cooling (0.7-1.0MPa) to prevent tool failure caused by high temperature.

Machine requirement

Spindle power ≥50kW, torque ≥100N·m, to ensure high rigidity processing.

2. Carbon fiber composite processing technology

Tool innovation

Diamond-tooth end mill: right-handed/left-handed edge alternating design, shear force balance, reduce delamination and burr.

Coating technology: Diamond coating (hardness 8000HV) improves wear resistance and extends life by 9 times.

Parameter adjustment

Speed: ≥12,000r/min, to achieve “milling instead of grinding”.

Cutting width and number of teeth: small cutting width, multi-tooth structure, improve surface quality.

Third, processing challenges and solutions

Tool wear and life

Titanium alloy: With PCD coating or asymmetric tooth design (such as anti-vibration end mill), life is increased by 4 times.

Composite materials: diamond-coated diamond teeth end mills reduce wear and adapt to the high hardness characteristics of carbon fiber.

Vibration and deformation control

Thin-walled parts clamping: multi-point light pressure to avoid deformation; Use high-precision tool handle (for every 100% increase in runout, life is reduced by 50%).

Anti-vibration design: Core thick groove type (large chip space in the front section, rigidity in the rear section) to reduce vibration.

Chips and safety

Titanium alloy: water-based or alkaline cutting fluid cooling fire prevention, prohibited chlorine solution.

Composite materials: Optimize the chute design to prevent chip blocking.

Fourth, typical cases and innovation direction

Anti-vibration end mill: The anti-vibration end mill developed by Shenzhen Aerospace Precision Tools can improve the efficiency of processing titanium alloy by 4 times through asymmetric tooth structure and variable core thickness design.

High pressure internal cooling technology: with the integral carbide end mill, to achieve efficient processing of titanium alloy (such as milling TC4 surface roughness of Ra1.6μm).

Through the above technology, the end mill achieves the balance of accuracy, efficiency and life in the processing of special materials in the orarms industry, and promotes the manufacturing upgrade of key components such as aviation and armor.