1、 Innovation in clamping technology

1. Flexible tooling design

Adopting modular hydraulic combination fixtures, adaptive clamping of irregular parts is achieved through multi reference positioning slots, with infinitely adjustable clamping force and pressure fluctuation ≤ 0.5%.

Use liquid expansion fixtures or imitation soft claws for complex surfaces to increase the contact area.

2. Stress dispersion strategy

During the rough machining stage, slotted sleeves are used for clamping, increasing the contact area by over 70%; Switching from precision machining to fan-shaped soft claws reduces clamping force by 40%~50%

Add auxiliary support frame to the overhanging structure, and offset the cutting torque through three-point contact elastic ejector pin

2、 Optimization of Processing Technology for Titanium Shaped Parts

Rough machining: Layered cutting method, using large rake angle tools (35 °) combined with high-pressure cooling;

Precision machining: Implement symmetrical machining strategy, adjust cutting parameters to small cutting depth+high feed rate;

Intermediate processing: After rough machining, vibration aging treatment is added, and the residual stress elimination rate can reach 75%.

3、 Improvement of cutting system

1. Tool parameters

The precision cutting tool is made of YA6 material, with a rake angle of 12 ° -15 ° and a tool tip arc radius of ≤ 0.2mm, achieving a 30% reduction in cutting force

By using PVD coated tools with chip breaking grooves, the tool life is increased by 2.5 times while suppressing the formation of chip deposits

2. Dynamic compensation

Embedding deformation compensation algorithm in CNC system, adjusting Z-axis feed rate based on real-time cutting force feedback

For parts with a length to diameter ratio greater than 10, the reverse cutting method is used to counteract the cutting tool effect

4、 Deformation correction methods

Online monitoring: Install laser displacement sensor (resolution 0.001mm) to monitor real-time processing deformation

Post processing: Three point pressure straightening method (pressure 500-800N) is used for deformed parts, combined with 200 ℃ low-temperature annealing to eliminate rebound

Summary: Through the systematic application of the above technologies, the machining deformation of titanium alloy irregular thin-walled parts can be controlled within 0.05mm/m, and the yield rate can be increased from 65% -92% of traditional processes. The key focus should be on the coordinated control of clamping system stiffness and cutting thermal management to avoid irreversible deformation caused by local stress concentration.