📋 Case Study
Aerospace Titanium Bracket Production Optimization
Excessive tool wear and inconsistent surface finish causing 22% scrap rate
🏗️ Project Overview
High-volume production of Ti-6Al-4V structural brackets for commercial aircraft
🎯 Challenge
Excessive tool wear and inconsistent surface finish causing 22% scrap rate
🔧 Design Approach
Adaptive roughing + trochoidal finishing with MQL delivery; revised toolpath segmentation and stepover reduction
📐 Design Diagram
AI-generated project design illustration
📐 Key Calculations
Optimal Chip Load
0.003 × Tool Diameter
Result: 0.045 mm/tooth
Prevents built-up edge on titanium
Thermal Load Index
SFM × DOC × WOC / Coolant Flow
Result: 1.8
Below threshold of 2.0 indicates safe thermal envelope
📊 Results
Tool life increased 3.2×, surface finish improved from Ra 3.2 µm to Ra 0.8 µm, scrap reduced to 4.1%💡 Lessons Learned
- •Titanium requires low chip load AND high spindle speed synergy
- •MQL flow rate must be calibrated per tool geometry
✅ Key Takeaways
- 1Titanium requires low chip load AND high spindle speed synergy
- 2MQL flow rate must be calibrated per tool geometry
📐 Prerequisites
Understand these before this topic
🔗 Engineering Applications
See how this applies across industries
Contact Us
- 📍 Weifang City, Shandong Province, China
- 💬 WhatsApp: +86 150 1018 9173
- ⚙ Cedar Li
- ✉️ Cedar@innovchip.net
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Updated: 2026-07-20
Reviewed by: ToolFusion Engineering Team