Titanium alloys may be strong, but they’re tough to machine! Thin sheet parts especially suffer from dimensional inaccuracies due to stress-induced deformation during cutting—a headache for many!
Don’t panic—a comprehensive solution can fix it: Adjust wire cutting and CNC milling paths, optimize machining plans, then enhance part rigidity with positioning fixtures and enclosed cutting methods.
This minimizes deformation at the source, ensuring consistent product quality!
Introduction
Titanium alloys boast high strength, corrosion resistance, heat resistance, and hardness, making them widely used in aerospace applications. Their drawbacks include poor thermal conductivity and challenging machinability.
The titanium alloy spacer part measures 43mm in length, 25mm in width, and 3.5mm in thickness.
The thickness and two central cavities are CNC-milled, while the eight external ribs are wire-cut to ensure rib widths of (0.3±0.05)mm and cavity symmetry within 0.05mm—classifying it as a fine-rib component.
During initial production, 10 parts were machined according to the process document. Inspection revealed that 4 parts failed to meet design requirements due to deviations in rib width and symmetry.
Cause Analysis
The original process document specified a raw material thickness of 5mm. However, due to inventory limitations at the facility, only 18mm thick material was available.
Consequently, the blank cutting dimensions were set to 250mm × 80mm with a thickness of 18mm, as shown in Figure 1.
An additional wire-cutting process was incorporated to halve the material thickness (see Figure 2), resulting in 9mm-thick sections. These sections were then CNC-milled to a final thickness of 3.5mm.
During CNC milling, operators use vacuum suction cups for clamping (see Figure 3). First, one surface is precision-milled to remove 3mm of stock.
After flipping and re-clamping the part, the second surface is milled to 3.5mm thickness. Finally, the internal cavity in the part’s center is machined.
Don’t panic—a comprehensive solution can fix it: Adjust wire cutting and CNC milling paths, optimize machining plans, then enhance part rigidity with positioning fixtures and enclosed cutting methods.
This minimizes deformation at the source, ensuring consistent product quality!
Introduction
Titanium alloys boast high strength, corrosion resistance, heat resistance, and hardness, making them widely used in aerospace applications. Their drawbacks include poor thermal conductivity and challenging machinability.
The titanium alloy spacer part measures 43mm in length, 25mm in width, and 3.5mm in thickness.
The thickness and two central cavities are CNC-milled, while the eight external ribs are wire-cut to ensure rib widths of (0.3±0.05)mm and cavity symmetry within 0.05mm—classifying it as a fine-rib component.
During initial production, 10 parts were machined according to the process document. Inspection revealed that 4 parts failed to meet design requirements due to deviations in rib width and symmetry.
Cause Analysis
The original process document specified a raw material thickness of 5mm. However, due to inventory limitations at the facility, only 18mm thick material was available.
Consequently, the blank cutting dimensions were set to 250mm × 80mm with a thickness of 18mm, as shown in Figure 1.
An additional wire-cutting process was incorporated to halve the material thickness (see Figure 2), resulting in 9mm-thick sections. These sections were then CNC-milled to a final thickness of 3.5mm.
During CNC milling, operators use vacuum suction cups for clamping (see Figure 3). First, one surface is precision-milled to remove 3mm of stock.
After flipping and re-clamping the part, the second surface is milled to 3.5mm thickness. Finally, the internal cavity in the part’s center is machined.
Titanium alloys may be strong, but they’re tough to machine! Thin sheet parts especially suffer from dimensional inaccuracies due to stress-induced deformation during cutting—a headache for many!
Don’t panic—a comprehensive solution can fix it: Adjust wire cutting and CNC milling paths, optimize machining plans, then enhance part rigidity with positioning fixtures and enclosed cutting methods.
This minimizes deformation at the source, ensuring consistent product quality!
Introduction
Titanium alloys boast high strength, corrosion resistance, heat resistance, and hardness, making them widely used in aerospace applications. Their drawbacks include poor thermal conductivity and challenging machinability.
The titanium alloy spacer part measures 43mm in length, 25mm in width, and 3.5mm in thickness.
The thickness and two central cavities are CNC-milled, while the eight external ribs are wire-cut to ensure rib widths of (0.3±0.05)mm and cavity symmetry within 0.05mm—classifying it as a fine-rib component.
During initial production, 10 parts were machined according to the process document. Inspection revealed that 4 parts failed to meet design requirements due to deviations in rib width and symmetry.
Cause Analysis
The original process document specified a raw material thickness of 5mm. However, due to inventory limitations at the facility, only 18mm thick material was available.
Consequently, the blank cutting dimensions were set to 250mm × 80mm with a thickness of 18mm, as shown in Figure 1.
An additional wire-cutting process was incorporated to halve the material thickness (see Figure 2), resulting in 9mm-thick sections. These sections were then CNC-milled to a final thickness of 3.5mm.
During CNC milling, operators use vacuum suction cups for clamping (see Figure 3). First, one surface is precision-milled to remove 3mm of stock.
After flipping and re-clamping the part, the second surface is milled to 3.5mm thickness. Finally, the internal cavity in the part’s center is machined.
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