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5-axis CNC Machining of Aerospace Scroll Stainless Steel Impeller
Release time:
Oct 23,2024
Project Background
YMP received an order from an aerospace customer to machine a batch of stainless steel scroll impeller for an aerospace turbine system. The material is SUS304 stainless steel. SUS304 has good corrosion resistance and mechanical properties, but the hardening tendency during machining and the high requirements for surface quality make this project very challenging. Since the scroll impeller is a core component of an aerospace engine, its machining accuracy and surface finish have a direct impact on the performance of the engine.
Challenges
Material Characteristics: The machinability of SUS304 stainless steel is poor, and it is prone to work hardening. Moreover, the coefficient of thermal expansion of this material is relatively high, and thermal deformation may occur during machining, affecting the dimensional accuracy and surface quality of the final product.
Geometric Complexity: The curved surface and spiral structure of the scroll impeller are complex, and it is difficult to achieve precise machining with traditional machining methods. The five-axis linkage machining path needs to be carefully planned.
High Precision and Surface Finish Requirements: Aerospace-grade parts have extremely high requirements for the shape accuracy and surface finish of the impeller to ensure stable operation and high efficiency under high-temperature and high-speed conditions.
Solutions
1. Equipment Selection
YMP uses a five-axis CNC machining center for the precision machining of scroll impeller. The five-axis linkage equipment can achieve continuous machining of complex curved surfaces, avoiding positioning errors caused by multiple clamping and ensuring high-precision machining of complex curved surfaces.
2. Optimization of Tools and Cutting Parameters
SUS304 material is prone to hardening during machining, so a coated carbide tool is selected. This tool has good wear resistance and high-temperature performance and can effectively reduce tool wear. By setting a lower feed rate and a medium cutting speed, combined with an efficient cooling system, the work hardening phenomenon is alleviated and the thermal deformation of the workpiece is reduced.
3. CAM Programming and Machining Path Planning
Advanced CAM software is used to simulate and optimize the machining path of the three-dimensional model of the scroll impeller in detail. A strategy of combining rough machining and finish machining is adopted. In the rough machining stage, a certain amount of allowance is reserved as much as possible to avoid errors caused by thermal deformation. In the finish machining, surface treatment is carried out with a small step of high precision to ensure the surface quality of the scroll impeller.
4. Quality Control and Online Measurement
During the machining process, an online measurement system is used. Through a precision probe, the thickness, curvature, and key dimensions of the impeller are monitored in real time to ensure that adjustments and compensations can be made at any time during the machining process to avoid machining errors. The final impeller product is detected by a three-coordinate measuring machine (CMM) and a dynamic balance machine to ensure that the errors of all key dimensions are controlled within ±3mm and the unbalance amount is within 0.09gmm, and the thinnest impeller thickness is 1.8mm.
5. Surface Treatment
After machining, the surface of the impeller is finely polished to achieve a surface roughness of Ra 0.2, ensuring that the fluid resistance is minimized when the turbine rotates at high speed and improving the working efficiency of the engine.
| Processing Name |
Aerospace Scroll Stainless Steel Impeller |
|
|||||||
| Using Equipment |
5 Axis CNC |
||||||||
| Processing Size |
Φ400mmX115mm |
||||||||
| Tools Quantity |
15 pieces
|
Machining Total Time |
180h55min |
||||||
| Serial Number |
Machining Steps |
Using Tools |
Ap (mm) |
Ae (mm) |
Spindle Speed |
Feed Speed |
Machining Time |
||
| 1 |
Rough Machining
|
R17R0.8 |
0.35 |
18 |
1500 |
2500 |
10:20:10 |
||
| 2 |
Finish Machining
|
R8R0.5 |
0.2 |
5 |
5000 |
3000 |
15:30:00 |
||
| 3 |
Finish Machining
|
D8R4 |
0.12 |
0.12 |
6500 |
3000 |
20:30:00 |
||
| 4 |
Finish Machining
|
D8R4 |
0.12 |
0.12 |
6500 |
3000 |
10:15:20 |
||
| Part Highlights:
|
|||||||||
| Checking Items |
Checking Reports |
||||||||
| Unbalance Amount (gmm) |
<0.09 |
||||||||
|
Dynamic Balance Machine |
||||||||
Results
High Precision and Consistency: The geometric accuracy of the impeller reaches the design requirements, with the error controlled within ±2 microns, ensuring the balance and stable operation of the turbine system.
Surface Finish: Through polishing treatment, the surface roughness of the scroll impeller reaches Ra 0.2, fully satisfying the strict standards of the aerospace industry.
Production Efficiency: Thanks to the efficient machining of the five-axis CNC equipment and the optimized process flow, the production cycle is shortened by 15%, and the production efficiency is significantly improved.
Customer Feedback: The customer is highly satisfied with the accuracy and surface finish of the scroll impeller. The product performs excellently in the turbine system test, further strengthening the cooperation with YMP.
Summary
This case demonstrates the strength of YMP in machining complex aerospace parts, especially in the high-precision machining of SUS304 stainless steel. Through five-axis CNC technology, reasonable tool selection, optimized machining path, and strict quality control, the high-quality machining of scroll impellers is successfully achieved, satisfying the demanding requirements of aerospace customers.
YMP,CNC machining , Impeller,Scroll impeller processing, stainless steel
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