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Founded in 1958, the Beijing Satellite Manufacturing Plant is the birthplace of China's first man-made earth satellite "Dongfanghong No. 1" and China's first spacecraft "Shenzhou No.1". 
Zhang Jiabo, Vice Minister of Mechanical and Electrical Products Division, Beijing Satellite Manufacturing Plant 
High quality, high precision, small batch size and difficult processing are typical features of spacecraft parts.
If quality problems occur during processing, the entire workpiece will be scrapped, affecting the manufacturing cycle and cost of the spacecraft. 
Walter Protostar N12 series T-slot milling cutter series has two types according to different coatings, and the coating is relatively sharp.
Suitable for processing aluminum alloy materials; TiCN coating is suitable for processing steel parts, which can extend tool life.
Walter application case: satellite manufacturing must also benefit from processing
Founded in 1958, Beijing Satellite Manufacturing Factory, affiliated to the Fifth Research Institute of China Aerospace Science and Technology Corporation, was the birthplace of China's first man-made earth satellite "Dongfanghong No.1" and China's first spacecraft "Shenzhou No.1". . After years of hard work, Beijing Satellite Manufacturing Plant has developed into a state-owned large enterprise specializing in spacecraft manufacturing. It has mastered domestic leading large-scale metal structure CNC machining, precision machining, composite material structure manufacturing, large-scale thin-wall metal structure welding and pipeline welding. , surface coating, non-destructive testing and on-board secondary power supply development, mechatronics product development and electronic assembly and other core technologies with distinctive aerospace characteristics.
During the "Tenth Five-Year Plan" period, many military industrial enterprises introduced a large number of high-end CNC machine tools. However, due to the backward technology and the lack of basic technology and supporting and management, the use efficiency of some CNC equipment was not high, which seriously restricted the performance of high-speed machine tools. Play. In order to improve the processing efficiency and utilization rate of high-speed machine tools, the Commission of Science, Technology and Industry for National Defense has arranged special high-efficiency cutting technology in the national defense science research plan, carried out technical research and demonstration applications, and carried out the development of thousands of CNC machine tools in the national defense science and technology industry. Engineering, comprehensive application of advanced numerical control technology and digital integrated manufacturing technology. As a technical support unit of the Aerospace Science and Technology Group, Beijing Satellite Manufacturing Plant (hereinafter referred to as the Satellite Plant) took the lead in carrying out this work and achieved good results by optimizing the cutting process to benefit from processing.
Indexable tool boosts efficiency
In the roughing of aluminum alloy workpieces, satellite plants use indexable tools instead of traditional carbide tools to achieve a win-win efficiency and cost.
Indexable tools play an important role in improving the efficiency of roughing to semi-finishing of aluminum alloy workpieces. The indexable tool is designed to be compact. When the tool is worn, only the blade needs to be replaced without removing the blade from the machine, which greatly reduces the downtime of the machine. Zhang Jiabo, deputy director of the mechanical and electrical products division of the satellite factory, has been engaged in machining for many years. He has a deep feeling about this: In the past, satellite factories used hard alloy tools to machine cavity parts, which caused serious tool wear and required frequent tool changes. Not only that, it takes at least 30 minutes to complete a cavity. With Walter's indexable tool, a cavity can be machined in just 5 minutes and the tool cost is significantly reduced. For example, processing a gyro support on a spacecraft requires machining a plurality of complicated cavities on a rectangular parallelepiped aluminum alloy material with a material removal rate of 80% to 90%. When machining the workpiece with a carbide tool, the tool has a large aspect ratio (>10), the process system is poorly rigid, the tool is prone to vibration, and the machining efficiency is low. It takes 2 weeks to process a workpiece. After using Walter's indexable tool, the satellite plant optimized the process path and now completes the machining of one workpiece in 5-6 days.
The tool body of the indexable tool has a very long service life, and the processing cost allocated to a single workpiece is negligible, and the cost of replacing the blade is much lower than the cost of grinding the welding tool, so the use cost is lower than that of the conventional cemented carbide. Tool. In addition, the coated blades wear very little, are interchangeable, and there is room for optimization.
The machining accuracy of a large number of joint parts in a spacecraft is extremely high, reaching 2 to 3 μm. In order to ensure the machining accuracy of these shaft and disc revolving parts, the satellite factory uses carbide tools for machining on the advanced Xiaobulin lathe. Practice has proved that the universal tool does not exist. Initially, in order to facilitate tool management, the satellite factory also used carbide tools in turning. Since the blade angle of the turning tool is not really a "tip", but has a certain curvature, and this arc is very difficult to control during the grinding process of the tool, although Beijing Satellite Factory has its own tool grinding workshop, However, the cost of using the turning tool has remained high. To this end, the satellite factory decided to try to make changes and choose a more economical processing method.
Longer tool life, smooth chip removal and shorter machining times are important indicators for turning. After a comprehensive comparison of a number of products, the satellite factory decided to use the combination of "Xiao Bulin lathe + Walter turning tool" to process these shaft and disc type rotary parts. Practice has proved that Walter has outstanding advantages in turning machining, and its turning tool has excellent performance and good cost performance. At the same time, Walter's turning experts also helped the Beijing Satellite Factory to plan and optimize the entire machining process to identify weak links, thereby improving the processing capacity of Xiao Bulin's machine tools.
Non-standard tools solve processing bottlenecks
High quality, high precision, small batch size and difficult processing are typical features of spacecraft parts. If quality problems occur during processing, the entire workpiece will be scrapped, affecting the manufacturing cycle and cost of the spacecraft. In addition, many parts on the spacecraft are unique in shape and complex in structure. Ordinary standard tools cannot meet the processing requirements, and only special non-standard tools can be used. For example, in the combined machining of spacecraft cabins, it is necessary to extend the tool to the back of the workpiece for machining, which is not possible with ordinary tools. To solve this bottleneck, the satellite plant used a T-slot milling cutter manufactured by tool manufacturer Walter. Protostar N12 series T-slot milling cutters are made of high-quality high-speed steel and can be used for T-slot forming milling. They can also be used to back-mill the back plane of the workpiece to meet the application requirements that ordinary milling cutters cannot meet. The tool features compact design, good stability, high machining accuracy, and can meet the requirements of use, and the delivery speed is fast.
In actual production, the quality problem caused by the processing of the size is always a key problem that plagues the processing efficiency. This is why many manufacturers have not introduced the expected performance of the advanced European machine tools, the cost is high, and the production efficiency is not high. The main reason. In this regard, Professor Li Liang of the School of Mechanical and Electrical Engineering of Nanjing University of Aeronautics and Astronautics has a very clear view. The application of advanced tool technology must be based on actual use and cannot be copied from foreign experience. Non-standard tools must be customized for the application, which puts higher demands on the tool supplier and must be supported by a specialized sales and technical service team. At present, the proportion of non-standard custom-made tools used by satellite plants is as high as 30% to 40%. Therefore, when choosing a tool supplier, the satellite factory is very cautious, reliable products are important, and reliable service and technical support are also necessary.
If you want to do something good, you must first sharpen it.
In the machining process, the selection of the tool and the determination of the parameters are very important, which determines the machining performance and processing efficiency of the machine tool. No matter how advanced the machine tool, if there is no advanced tool support, then its excellent performance can not be played properly.
From the experience of satellite manufacturers, although the replacement period of machine tools is very long, the innovation of cutting technology is in the new moon, which is of great significance to improve the efficiency and quality of machining. The selection of tools needs to be combined with the actual machining conditions, advanced applicable tools and reasonable processing parameters to maximize the performance of high-speed machine tools and reduce processing costs. In addition, the technicians who produce the first line also need to constantly update the knowledge and adjust the existing processing methods and tools.
While providing users with tooling products, Walter is more focused on how to make users better use their tools to increase productivity. As the Deputy Minister Zhang Jiabo said, each excellent tool brand has its own characteristics and specialties. Only when the manufacturer selects and uses the tool correctly according to its own equipment conditions and processing requirements can it achieve the desired return. The cooperation with Walter has benefited the satellite factory.