[Core demands of processed products]
A certain aerospace technology company needs to perform precision processing on silicon carbide ceramic-based composite material workpieces, involving profile milling and micro-hole drilling with a diameter of 0.8-3.2mm. The material has a density of only 2.7g/cm³, a Vickers hardness of 28GPa, and a thermal expansion coefficient close to zero. It is used in the thermal protection system of new hypersonic aircraft.
[Industry processing pain points]
In the field of aviation composite material processing, traditional processes face three major technical bottlenecks:
1) Cutting fluid prohibition restrictions: The contact between materials and liquid media will cause intergranular corrosion, resulting in a 15%-22% decrease in structural strength
2) Dry cutting defects: When the spindle speed reaches 18,000 rpm, the tool wear rate is 8 times higher than that of ordinary metal processing
3) Surface quality control: The surface roughness of the workpiece after processing must be ≤Ra0.4μm, and the pass rate of traditional processes is less than 35%
[MID solutions technology innovation]
In response to the processing difficulties of high-temperature ceramic-based composite materials, the MID R&D team uses innovative composite processes:
1. Multi-axis linkage ultrasonic green engraving and milling system: Axial vibration cutting with amplitude ±5μm and frequency of 20kHz
2. Supercritical CO2 low-temperature auxiliary technology: -78℃ microparticle jet precise temperature control
3.Customized PCD tool coating: three-layer gradient structure design, cutting edge arc radius ≤2μm
[Process upgrade results]
Compared with traditional processing methods, this solution has achieved a number of breakthroughs:
■ Peak cutting force reduced by 36% (measured data 412N→263N)
■ Tool life extended to 7.8 hours (original 1.2 hours)
■ Surface roughness Ra0.32μm compliance rate 91%
■ Processing efficiency increased by 4.3 times (single-piece working hours reduced from 14 hours to 3.25 hours)
MID Company Profile: 16 years of experience in special material processing, focusing on customized solutions for difficult-to-process materials such as aerospace composite materials, ceramic-based high-temperature resistant components, and carbon fiber reinforced plastics.
