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DE Case 1: A Military Group (Yun-20 Transport Aircraft Honeycomb Structure Machining)
Challenge:
Processing honeycomb structures in aerospace aluminum alloys is susceptible to deformation. Traditional tools experience significant vibrations and have a lifespan of less than 30 minutes.
Solution:
A customized 600mm diameter carbide end mill was developed with an optimized helix angle, anti-vibration coating, and additional chip evacuation flutes.
Results:
Machining efficiency improved by 50%, tool life extended to 2 hours, meeting the annual production target of 50 aircraft.
Case 2: Huawei Technologies (High-gloss Chamfering on Metal Frames of Smartphones)
Challenge:
Micro-radius chamfering (R0.05mm) on titanium alloy frames requires a mirror finish with tight tolerances of ±0.003mm.
Solution:
A 0.2mm ultra-fine grain tungsten carbide ball nose end mill was employed, featuring a PVD nano coating and dynamic balancing design.
Results:
The yield rate improved from 82% to 98%, and the tool demonstrated the capability to continuously machine 8,000 pieces without any chipping.
Case 3: A New Energy Vehicle Motor Housing Supplier
Challenge:
Deep cavity machining of silicon aluminum alloy motor housings resulted in significant chip adhesion, leading to surface roughness exceeding Ra1.6.
Solution:
A variable rake angle step milling cutter was developed, paired with a TiAlCrN coating to reduce the friction coefficient.
Results:
Processing time per piece was reduced by 25%, tool life tripled, and annual cost savings reached RMB 1.2 million.
Case 4: China's Top Cable Mold Company (Carbide Core Processing)
Challenge:
Machining cavities in HRC65 carbide cores using traditional tools resulted in a chipping rate exceeding 40%.
Solution:
A spiral end mill with a dual-layer composite coating (AlTiN+MoS2) was used, along with optimized edge honing processes.
Results:
Processing efficiency increased by 35%, core precision reached IT5 grade, and customer reorder rate reached 100%.
Case 5: A Spacecraft Fuel Tank Manufacturer
Challenge:
Machining thin-walled Inconel 718 high-temperature alloy components (2mm thick) resulted in deformations exceeding 0.1mm.
Solution:
A customized milling cutter with small cutting depth and high feed rates, featuring negative rake angle design and high-pressure internal cooling channels.
Results:
Deformation was controlled within 0.03mm, and tool life reached 2.2 times the industry standard.
Case 6: A Leading Medical Device Manufacturer (Cobalt-Chromium-Molybdenum Alloy for Artificial Joints)
Challenge:
Processing biocompatible materials often produces burrs, with cleanliness requirements meeting ISO Class 5 standards.
Solution:
A specialized 5-axis polishing end mill with nanodiamond coating and special edge reinforcement technology.
Results:
Surface roughness achieved Ra0.2μm, completely eliminating the need for subsequent manual polishing.
Case 7: A Wind Turbine Blade Mold Supplier
Challenge:
Machining glass fiber composite materials caused delamination defects, with tool wear occurring at 10 times the rate of metal machining.
Solution:
A polycrystalline diamond (PCD) coated milling cutter with a 72° helix angle optimized for fiber cutting.
Results:
Mold life extended to 800 hours, and machining dust reduced by 60%.
Case 8: A High-Speed Rail Gearbox Supplier
Challenge:
Gear tooth profile machining of 18CrNiMo7-6 carburized steel took 180 minutes per piece.
Solution:
Modular indexable gear milling cutters with double positive rake angle inserts.
Results:
Processing time compressed to 110 minutes, and tool change frequency reduced by 70%.