Coated saw blade milling cutters are divided into four categories: coated hard alloy saw blade milling cutters, coated high-speed steel saw blade milling cutters, diamond coated saw blade milling cutters, and CBN coated saw blade milling cutters. Relying on the high-temperature resistance, low friction, wear resistance, and anti sticking characteristics of coatings, they specialize in solving the problems of slotting, cutting, slitting, and narrow groove precision machining of aviation titanium alloys, high-temperature alloys, aviation aluminum, carbon fiber composites, and laminated composite plates, covering the entire industry chain of aircraft structural components, aviation engines, and aerospace rocket parts processing.
1、 Processing aviation aluminum alloy fuselage structural components (7075/2024/6061 aviation aluminum)
1. Typical machined parts
Wing stiffeners, fuselage frame beams, landing gear aluminum supports, cabin door aluminum profiles, aircraft skin connection strips, aluminum alloy pipeline brackets, unmanned aerial vehicle aluminum fuselage frame.
2. Core machining process (exclusive for saw blades and milling cutters)
Narrow groove/semi closed deep groove milling: part weight reduction groove, assembly guide groove, buckle positioning narrow groove, groove width 0.3~3mm, long groove one-time molding;
Cutting and slitting of profiles: cutting of long aluminum profiles to a fixed length, batch support cutting;
Cutting seams and chamfering on the side of the convex platform for root cleaning: cleaning the root of the thin-walled rib plate to remove excess excess space;
Processing of small annular grooves for flange sealing rings.
3. Suitable coating and function
Using TiN, TiCN, DLC diamond coated saw blade milling cutters:
The coating has a low friction coefficient, which prevents aluminum chips from sticking to the knife and forming chip lumps, and avoids surface scratches and burrs on the workpiece;
Improve cutting line speed, increase machining efficiency by 30%~60%;
Processing thin-walled aluminum parts reduces cutting vibration, ensuring a groove width tolerance of ± 0.01mm and a high smoothness with Ra ≤ 0.8 μ m;
The uncoated high-speed steel saw blade is prone to sticking teeth when processing aluminum, and the coated tool life is increased by 2-4 times.
2、 Processing of titanium alloy components (TC4/Ti6Al4V, TC21, high-temperature titanium alloys, difficult to machine aviation core materials)
1. Typical machined parts
Engine titanium casing thin-walled ring, titanium alloy integral blade splitter groove, landing gear titanium joint, rocket fuel tank titanium flange, aviation hydraulic titanium pipeline, drone titanium skeleton, blade tenon groove auxiliary slotting.
2. Core processing procedures
Milling of deep and narrow weight reducing grooves: Axial long grooves (up to 400mm in length) on the inner wall of titanium thin-walled annular parts. Traditional end mills have lower cutting efficiency, and saw blade milling cutters can form through grooves in one go;
Cutting and cutting of titanium rods/forgings: batch segmentation of rod materials;
Processing of sealed small annular grooves and narrow grooves in oil circuits;
Groove and divide multiple titanium alloy blanks on the side of the rib plate.
3. Adaptation coating and process advantages
Standard AlTiN, TiSiN nano multilayer composite coating hard alloy saw blade milling cutter:
Titanium alloy has extremely poor thermal conductivity, with cutting heat concentrated at the cutting edge. The AlTiN coating generates an aluminum oxide insulation film at high temperatures, which can withstand high temperatures up to 800 ℃ and significantly reduce high-temperature wear of the cutting edge;
Inhibit titanium alloy work hardening, reduce sawtooth and crescent wear, and the tool life under the same working conditions is more than 5 times that of uncoated saw blades;
Thin tooth ultra-thin saw blade milling cutter (0.5-1.5mm) with coating, reduces cutting force when processing thin-walled parts, and prevents titanium parts from rebounding and deforming;
Experimental data: The continuous cutting length of titanium alloy processed by coated hard alloy saw blades is greater than 1200mm, while coated high-speed steel is only 250mm, and ordinary high-speed steel is less than 100mm.
3、 Nickel based high-temperature alloy processing (GH4169/Inconel718, Hastelloy, hot end parts for aircraft engines)
1. Typical parts
Aircraft engine turbine casing, combustion chamber bracket, high-temperature sealing ring, turbine blade fixing seat, gas duct, rocket engine high-temperature valve body.
2. Core processing procedures
Cutting and splitting of high-temperature alloy forgings into blanks;
Processing of sealed narrow ring grooves and small grooves for cooling medium circulation;
Install the convex platform side seam and position the keyway milling;
Layered slotting rough machining of thick walled high-temperature alloy parts.
3. Special coating: CBN coating/high aluminum TiAlN composite coating saw blade milling cutter
Nickel based alloys have extremely strong work hardening, high cutting force, and temperatures exceeding 1000 ℃, causing rapid failure of ordinary coatings;
CBN coating is thermally stable at 1300 ℃, resistant to plastic wear and impact, and has a tool life 10 times longer than ordinary coated hard alloys;
Multi layer TiAlN gradient coating alleviates the risk of serrated edge breakage and is suitable for intermittent slotting conditions;
Resolve issues such as sticking to high-temperature alloy cutting tools, surface burns on workpieces, and out of tolerance groove dimensions.
4、 Carbon fiber composite material CFRP, honeycomb sandwich, metal composite laminate processing (for civil aviation large aircraft, unmanned aerial vehicle main body)
1. Typical parts
CFRP wing skin, fuselage composite wall panels, composite landing gear fairings, drone carbon fiber fuselage, carbon fiber titanium alloy laminated connecting plates, honeycomb sandwich structural components.
2. Core processes
Fixed length cutting and side cutting of composite boards;
Milling of assembly narrow slots, rivet avoidance slots, and weight reduction slots;
Layered cutting of laminated plates (carbon fiber+titanium/aluminum laminated plates) to avoid delamination and tearing;
Precision machining of composite flange annular sealing groove.
3. Compatible tool: Diamond (CVD) coated hard alloy saw blade milling cutter
Carbon fiber has high hardness and strong abrasion resistance, and uncoated saw blades experience severe wear after processing for tens of meters; The hardness of the diamond coating is 10000HV, and the wear resistance is increased by more than 10 times;
Sharp cutting edge, low axial cutting force, suppresses composite delamination, fiber fuzzing, edge tearing, and reduces part scrap rate;
The coating surface is smooth, and carbon powder is less likely to adhere to serrations, reducing the need for repeated cleaning of cutting tools;
Compared to PCD welding saw blades, diamond coated saw blades have lower costs and can process complex narrow grooves, making them suitable for small and medium-sized precision composite parts.
5、 Aviation stainless steel and high-strength heat-resistant steel components
1. Scope of parts
321/316 stainless steel fittings for aviation pipelines, rocket propellant valves, engine high-temperature exhaust housings, and aircraft hydraulic stainless steel valve bodies.
2. Process: Cutting of stainless steel rod, milling of sealing groove and narrow groove of oil circuit
3. Coating: TiAlN and TiCN coated saw blades to resist cold work hardening and sticking during stainless steel processing.
6、 Special application scenarios in the aerospace subdivision field
（1） Civil aircraft manufacturing (C919, CR929, Boeing, Airbus)
Batch milling of weight reducing slots for the aluminum lithium alloy frame beam of the fuselage;
Cutting of CFRP wing panels, slotting of splicing seams;
Precision machining of narrow grooves in the oil circuit of titanium alloy landing gear joints;
Processing of annular sealing groove for high-temperature alloy engine casing.
（2） Aircraft engine manufacturing (core difficult scenarios for aviation engines)
Forming of narrow cooling slots and diversion slots on the inner wall of Inconel718 receiver;
Slotting of diversion joints between titanium alloy integral blade discs and blades;
Cutting and keyway processing of high-temperature alloy bracket for combustion chamber;
Cut and clean the edges of the titanium alloy tenon on the blade.
（3） Space launch vehicles, missile components
Titanium alloy fuel pipeline annular groove for liquid oxygen kerosene engine;
Slot for reinforcing ribs of 7075 aluminum alloy storage tank for rocket body;
Processing of micro grooves for high-temperature alloy nozzle cooling;
Cutting and positioning groove processing of composite material satellite bracket.
（4） Lightweight parts for unmanned aerial vehicles and general aviation aircraft
Cutting and narrow groove processing of all carbon fiber body frame;
Batch slotting and cutting of small titanium alloy and aluminum alloy lightweight brackets.

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