Analysis of processed product characteristics
Workpiece material characteristics:
The titanium alloy TC4 metal bracket processed this time has high strength and corrosion resistance, and is widely used in the aerospace field. The material hardness reaches HRC36-40, which is a typical difficult-to-process alloy material.
Processing process characteristics:
Five-axis linkage milling process is adopted
Multi-angle drilling is required at thin walls
Processing allowance needs to be controlled within the tolerance zone of ±0.05mm
In-depth analysis of industry processing pain points
The current metal processing industry generally faces three major technical bottlenecks:
Thin-wall processing deformation control problem
• The original titanium plate thickness of 25mm is processed to 0.3-0.5mm finished product
• The deformation rate of traditional process reaches 38% (data source: JMP Precision Manufacturing Report)
Surface quality improvement dilemma
• Conventional milling surface roughness is only Ra1.6μm
• Post-processing process increases production cost by 25% (based on 2023 IMTS survey)
Efficiency and cost balance problem
• Manual deburring accounts for 30% of the total working time
• Tool wear costs account for 18% of the total processing cost
MID solution technology innovation
In response to the special needs of TC4 thin-walled parts processing, the ultrasonic green lightweight vertical five-axis machining system we developed includes three core technological breakthroughs:
High-frequency ultrasonic vibration spindle
• 40kHz high-frequency vibration technology
• Cutting force reduced by more than 60%
Intelligent compensation processing system
• Real-time deformation monitoring compensation
• Machining accuracy improved to ±0.01mm
Online deburring module
• Integrated abrasive flow processing unit
• Realize machining-deburring integration
Comparative advantages of MID solution
Machining quality significantly improved
• Ra0.4μm mirror effect (increased by 300%)
• 100% surface fit (visually seamless)
Revolutionary breakthrough in production efficiency
• Single-piece processing time shortened by 42%
• Tool life extended by 3.8 times
Comprehensive cost optimization
• Manual intervention reduced by 75%
• The scrap rate has dropped to below 0.3%
MID Company Profile:
With more than 10 years of experience in precision machining, MID has built a complete technical system covering five-axis machining centers, ultrasonic auxiliary systems, and intelligent testing equipment. Focusing on the research and development of innovative processing solutions for special materials such as titanium alloys and high-temperature alloys, MID serves more than 300 customers in the aerospace and medical device fields around the world. With ISO 13485 medical certification and AS9100D aerospace certification, MID continues to provide customers with cost-effective customized processing solutions.
