Aeroengine fuel accessories key parts composite processing

Chen Jianxin (left) and Yan Qi (right), First Class Experts from Xi'an Aerospace Power Control Co., Ltd., AVIC Engine Group

The aero engine fuel accessory plays a crucial role in supplying and dynamically adjusting the fuel needed by the engine based on its operational conditions and the aircraft’s flight status. This ensures the aircraft’s maneuverability, accuracy, and safety. Modern aero engine fuel systems typically include a main fuel system, an afterburner system, a flow regulation system, an emergency oil drain system, and a drainage system. Due to the complexity of these components, advanced technologies such as special processing and composite machining are essential to overcome manufacturing challenges and reduce costs. Composite machining significantly shortens the production cycle, reduces inventory, supports just-in-time manufacturing, minimizes workpiece setups, avoids installation errors, improves accuracy and stability, and enhances control over fuel accessories. This ensures the engine operates safely and efficiently, maximizing its performance. Below is an example of the machining process for the induction wheel using the S191 Linear Turn-Milling Machining Center.

Part Structure and Material

The part is made from TC4 titanium alloy, known for its high strength, hardness, toughness, and elongation. However, it has poor thermal conductivity, significant surface work hardening, and challenging cutting properties. The induction wheel is part of the impeller fuel pump and is located at the front end of the impeller. Its inner surface is a rotating body, finished through turning, while the outer surface features evenly distributed blades, completed via milling. At both ends, there are face grooves and radial square holes, making it a classic example of turn-milling composite machining (see Figure 1).

Figure 1: Three-dimensional model of the induction wheel

2. Equipment Selection

The S191 Linear Turn-Milling Machining Center was selected for this task. This seven-axis CNC machine combines the advantages of a five-axis machining center with a two-spindle turning center. It allows for five-axis linkage processing on both the front and back parts. The Y and Z axes are driven by linear motors in a horizontal plane, and the rear spindle can be rotated vertically or horizontally, enabling high-precision machining in both orientations (see Figure 2).

Figure 2

3. Machining Process

Through detailed process analysis, it was found that the part has a large machining allowance, and the blade thickness is only 2mm. Large-margin machining can cause significant deformation. Therefore, stress relief steps and angular orientation must be considered during the process. Since the device features a dual-spindle function with an extended process head at the small outer circumference, the positioning hole is also placed here, ensuring no error occurs due to secondary clamping. Based on the principle of completing multiple processing tasks under one clamping, the process route was determined as follows: rough turning and boring, drilling the positioning hole and deburring, rough milling, stabilization, grinding, fine turning, final milling, square hole milling, cone surface turning, groove milling, and final inspection. Roughing operations were performed on a lathe and CNC machine. From a cost and precision perspective, roughing could not be done on this equipment. Finishing, including fine turning, deburring, cone surface turning, and groove milling, was alternately performed by the dual-spindle of the turn-milling machining center, with positioning done in one setup. By utilizing turn-milling composite technology, the process was optimized, fully leveraging the machine tool’s capabilities, shortening the process route, improving reliability, increasing efficiency, reducing costs, and ensuring high-quality results. Advanced material technologies and modern manufacturing methods form the foundation of aerospace innovation. To enhance processing quality and productivity, it is essential to research and apply efficient and diverse composite machining techniques.

Low Type Heavy-duty Industrial Caster

Low Type Heavy-Duty Industrial Caster,Industrial Caster,Nylon Wheel,Universal Casters

BENYU CASTERS & WHEELS CO.,LTD , https://www.benyucaster.com