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Application of turning-milling machine tool in production site
In aerospace manufacturing, the integration of advanced materials and cutting-edge technologies plays a crucial role in enhancing aerodynamic performance. However, during the production process, a significant amount of time is often spent on handling, transferring workpieces, and setting up tools—factors that can hinder efficiency and quality. To address these challenges, it's essential to minimize such non-cutting time, improve overall processing efficiency, and ensure high-quality results. This is where composite machining comes into play.
Composite machining involves using a single machine to perform multiple operations, reducing the need for frequent workpiece transfers and minimizing errors caused by repeated clamping. It allows for the simultaneous processing of several parts or different operations on a single part, making it ideal for small batch or single-unit production in the aerospace industry. The following discussion explores some of the issues encountered when using turning and milling machine tools in this context.
The unit has recently acquired three advanced machine tools: the S189 twin-spindle, double-turret, six-axis turning and milling center (Figure 1), the S191 five-axis linkage milling and turning center (Figures 2 and 3), and the S192 horizontal milling and turning center (Figures 4 and 5). During the initial phase of using these machines, there were challenges related to understanding the turret, spindle, and programming methods. For milling and turning centers, the primary goal is to eliminate secondary clamping errors, thus improving part accuracy and processing efficiency. These machines allow for multiple parts to be processed at once or for several turrets to work on a single part simultaneously.
When planning the manufacturing process, it's important to design a workflow that fully leverages the capabilities of these complex machines rather than simply combining traditional machining steps. Turning and milling machines are not just simple combinations of lathes and milling machines—they are highly sophisticated systems with unique features, such as inner loops, that significantly enhance their value. However, manual programming is often inefficient and risky, especially when multiple turrets are involved. Operators may struggle to predict collisions or manage complex movements, which can lead to downtime.
To overcome these challenges, it's essential to use professional software for programming and simulation, such as TopSolid, GIBBS, and EdgeCam. These tools help maximize machine utilization and meet tight processing deadlines. The complexity of these machines means that relying solely on manual operation is not only inefficient but also unsafe. Therefore, investing in specialized software is crucial to unlocking the full potential of composite machining equipment.
Currently, the aerospace industry is moving toward more customized and smaller-scale production. This trend makes the use of advanced machine tools even more critical, requiring a reliable technical system and platform to support full-process computer control. With automated loading, unloading, and deburring processes, the entire production cycle can be streamlined, resulting in high-quality and efficient outputs.
Composite machining highlights the importance of multi-step processing within a single clamping operation, which enhances the accuracy of the final product. While the initial investment in composite machining equipment is high, the long-term benefits in terms of quality, efficiency, and cost savings are substantial. To fully utilize these machines, it’s also important to provide proper training to operators, ensuring they can respond quickly to product development needs and maintain a competitive edge.
**About the author:** Zhao Xinglong (born in 1982) is an engineer specializing in gear turning and grinding, as well as the machining of difficult-to-process materials.
**Unit Name:** Xi'an Aviation Power Control Company
**Activity Background:** In recent years, China's equipment manufacturing industry has experienced rapid growth, driven by the continuous development of machine tools. As the saying goes, "A sharp knife doesn’t miss the firewood"—high-quality tools not only boost productivity but also reduce costs. This article was submitted to the "Machine Tool Use Evaluation and Experience" competition, organized by Metal Processing Online, discussing the advantages and limitations of the machine tools currently used in the company and sharing personal experiences and insights.