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Precautions During the Machining Process of Titanium Alloy Components

Precautions During the Machining Process of Titanium Alloy Components

2025-07-10

The cutting process of titanium alloy involves high-force machining, requiring machine tools with high spindle drive power and strong cutting capabilities. In the aerospace industry, the machining of titanium alloy parts primarily involves cavity milling. To facilitate chip removal, the cooling and lubrication system must be properly managed. To ensure efficient chip evacuation, a high-pressure cooling and lubricant delivery system should be implemented to directly spray large volumes of coolant onto the cutting tool. This serves two purposes: cooling the tool and promptly flushing chips out of the machining area to prevent recutting, which shortens tool life and scratches the machined surface.

To enable high-power machining capabilities, manufacturers of titanium alloy components specifically design product structures and coordinate axis configurations, equipping them with powerful cutting and swing units. The tool spindle mounting system exhibits excellent rigidity, allowing the machine tool to generate consistent cutting force at any angle—vertical, horizontal, or spatial.

Titanium alloys are characterized by high strength and poor thermal conductivity. To achieve machining efficiency comparable to that of aluminum, it is necessary to maximize cutting parameters, such as increasing feed rates and cutting depths. However, this leads to higher cutting forces, which may cause static deviation between the workpiece and the tool, resulting in reduced part accuracy or unstable machining processes. It also accelerates tool wear. Therefore, machines used for titanium alloy machining must possess high power and exhibit excellent static and dynamic characteristics (high static and dynamic stiffness). Additionally, they must be equipped with corresponding high-pressure cooling and lubrication systems to facilitate low-speed, high-torque machining. Timely chip removal is crucial to reduce tool wear and minimize heat generation during machining.

To enhance machine rigidity, some manufacturers employ welded steel structures in box-type or closed-frame designs. High-power feed motors for the axes and high-stiffness, zero-backlash guide systems ensure stability in the machining position, further improving machine rigidity. Moreover, the entire system, including the spindle-tool connection and tool holder, must be optimized for stiffness during machining.

In addition to static stiffness, the dynamic characteristics of the machine tool play a decisive role in the efficient machining of titanium alloys. Ensuring process stability is a significant challenge. If the machine tool has low rigidity and poor damping characteristics, self-excited vibrations may occur due to high cutting forces during machining. Low rotational speeds and excitation frequencies close to the natural frequency of the machine tool can cause chatter during machining. Apart from affecting the surface quality of the workpiece (e.g., leaving chatter marks), this vibration can damage the machine structure, tool holder, and tool, leading to increased tool wear or even breakage.

The stability of the machining process largely depends on parameters such as spindle speed and selected cutting depth. Users should understand the performance of their machine tools and the achievable limits of cutting depth. Additionally, anti-vibration pads can be proactively installed on the machine, and parameters can be pre-set in the machine control system to avoid critical cutting depth ranges that induce vibrations.