Overcoming challenges: advancements in cutting techniques for high strength-toughness alloys in aero-engines

• Published in: International Journal of Extreme Manufacturing Vol. 6; no. 6; pp. 62012 - 62080
• Main Authors: Zhao, Biao, Wang, Yufeng, Peng, Jianhao, Wang, Xin, Ding, Wenfeng, Lei, Xiaofei, Wu, Bangfu, Zhang, Minxiu, Xu, Jiuhua, Zhang, Liangchi, Das, Raj
• Format: Journal Article
• Language: English
• Published: Bristol IOP Publishing 01-12-2024
• Subjects: Aerospace engines; Air transportation; Computer program integrity; controlling the shape and surface integrity technology; Cryogenic cooling; Cutting force; Cutting parameters; Cutting tools; Cutting wear; energy-assisted machining technology; Engines; High strength alloys; High strength steels; Intelligent manufacturing systems; intelligent monitoring technology; Intermetallic compounds; Laser cooling; Machining; Monitoring; Nickel base alloys; Shape effects; Software; Superalloys; Surface roughness; Titanium alloys; Titanium base alloys; tool preparation technology; Tool wear; Toughness
• ISSN: 2631-8644; 2631-7990
• DOI: 10.1088/2631-7990/ad8117

Abstract Aero-engines, the core of air travel, rely on advanced high strength-toughness alloys (THSAs) such as titanium alloys, nickel-based superalloys, intermetallics, and ultra-high strength steel. The precision of cutting techniques is crucial for the manufacture of key components, including blades, discs, shafts, and gears. However, machining THSAs pose significant challenges, including high cutting forces and temperatures, which lead to rapid tool wear, reduced efficiency, and compromised surface integrity. This review thoroughly explores the current landscape and future directions of cutting techniques for THSAs in aero-engines. It examines the principles, mechanisms, and benefits of energy-assisted cutting technologies like laser-assisted machining and cryogenic cooling. The review assesses various tool preparation methods, their effects on tool performance, and strategies for precise shape and surface integrity control. It also outlines intelligent monitoring technologies for machining process status, covering aspects such as tool wear, surface roughness, and chatter, contributing to intelligent manufacturing. Additionally, it highlights emerging trends and potential future developments, including multi-energy assisted cutting mechanisms, advanced cutting tools, and collaborative control of structure shape and surface integrity, alongside intelligent monitoring software and hardware. This review serves as a reference for achieving efficient and high-quality manufacturing of THSAs in aero-engines.
Highlights The energy field assisted mechanical processing technology methods and development status are introduced. The development of tool preparation technology for high-strength and toughness materials is elaborated. The development of collaborative technologies of structure shape and surface integrity is summarized. The development of intelligent monitoring technology is summarized. The development and sustainability of advanced cutting technologies for high strength-toughness alloys in aero-engines are prospected.