Open AccessEssentially, new constructive solutions, among which there are such as application of highstrength aluminum alloys for large-size case parts with the wafer design of the shell (WDS) characterize modern and perspective products of the missile and space equipment (MSE). To define optimum strategy of WDS pocket treatment, the paper presents a strategy analysis of penetration and treatment in CAID "ADEM". Based on the performed optimization a combination "spiral" and penetration "spiral on a contour" has been accepted as a strategy of the pocket treatment.
To optimize the cutting modes, taking into consideration an elimination of the WDS element deformations, are calculated the hard-alloy mill forces, temperatures, wear rate, size of wear, and tool life, when milling a pocket as a standard element of WDS. A calculation technique which distinctive feature is to take into account the forces and pressure from the face edge of a mill tooth is used. In particular, there is functional relationship between the wear rate of a back surface of the tool and the generalized parameter, i.e. the cutting speed relation to hardness of the wearing tool surface as a function of the cutting temperature for milling conditions of aluminum alloys on the modern CN equipment.
The paper presents a sequence of formulas implemented as a calculating algorithm and appropriate calculating program. It shows power and polynomial equations obtained to establish relations of the tool life and a torque of cutting with the variable parameters, i.e. the speed, depth, feed, mill diameter and width.
Modeling and optimization results show that for rough treatment of grooves, a technological restriction is machine spindle power. With fine finish and penetration a feed of the tool has to be restricted to prevent deformation of a pocket bottom.
During treatment of pockets in large-size parts with WDS a lag effect of the linear drives of equipment has to be taken into consideration, when feeding.
The optimum milling modes are advisable for using in technological processing of the MSE parts from high-strength aluminum alloys.