Tool Wear in Disc Milling Grooving of Aircraft Engine Blisk

Disc milling is a new technology applied to machine blisk, which can improve the processing efficiency of blisk 3–4 times compared to the existing technology. However, the tool wear rate is very fast because of big milling force and high temperature during disc milling process, so the tool life is seriously reduced. In the study, in order to study how to enhance tool life, the disc milling experiment of blisk is designed. First, the tool life curve is plotted according to the average flank wear growth. Then, the wear morphology of disc cutter is detected with scanning electron microscope. Last, the corresponding mechanisms are analyzed with an X-ray energy-dispersive spectrometer. Experiment results show that the wear differentiation of left/right blade is found because of the overhanging installation way and staggered structure of disc cutter, and 84% channels can be done before disc cutter is blunt. The wear morphology mainly has spalling, crack and flank wear. The corresponding wear mechanisms mainly have adhesion wear, oxidation wear and diffusion wear. The search results will provide experimental support and theoretical basis to how to enhance tool life.