Optimization of Cutting Processes and Efficiency Improvement for Difficult-to-Machine Materials in Precision Machining of Aerospace Blades

Abstract

Precision machining of aerospace blades involves processing materials that are often difficult to machine, such as titanium alloys, nickel-based superalloys, and high-strength steels. These materials pose challenges including rapid tool wear, poor surface finish, and low material removal rates, which directly affect production efficiency and component performance. This study investigates the optimization of cutting parameters, tool geometries, and process strategies to enhance machining efficiency while ensuring dimensional accuracy and surface integrity. Using experimental trials and process simulations, we identify key factors influencing cutting forces, tool life, and thermal effects. The results demonstrate that optimized cutting conditions can significantly improve material removal rates, reduce tool wear, and enhance surface quality, providing practical guidance for high-precision aerospace blade manufacturing.