Technological features of machining complex aerospace components using multi-axis strategies and advanced cam approaches

The technological features of the mechanical machining of complex aerospace components, which are characterized by intricate three-dimensional geometry, thin-walled elements, deep cavities, and stringent requirements for the quality of formed surfaces, are examined in this study. Such products include compressor impellers, integrally bladed disks (blisks), and structural housing components of aircraft and space systems. It is demonstrated that the increasing geometric complexity of modern aerospace parts limits the efficiency of conventional milling methods based on 2.5-axis and positional machining strategies, which is manifested in increased tool overhang, reduced stiffness of the technological system, higher vibration levels, and deterioration of the machined surface quality. The aim of this work is to provide an analysis of modern CAM approaches to toolpath generation for machining parts with complex spatial forms and to substantiate the feasibility of implementing multi-axis machining strategies. Within the framework of the research, the design features of aerospace components are considered and the technological factors affecting cutting process stability, shaping accuracy, and machining productivity are identified. Particular attention is paid to current methods of toolpath calculation in CAM systems, including residual stock consideration, the application of adaptive and multi-pass strategies, and the use of updated stock models based on three-dimensional representations. The capabilities of five-axis machining are separately analyzed, including the use of “3+2” positional schemes and simultaneous five-axis strategies that allow for the optimization of tool orientation relative to the machined surface, a reduction in tool overhang, and an increase in the stability of the cutting process. The efficiency of using circle-segment end mills (barrel tools) is demonstrated, as they allow for an increase in the effective contact radius, a reduction in the number of machining passes, and an improvement in surface roughness parameters during finishing operations. The results obtained can be utilized in the development and optimization of technological processes for machining complex aerospace components on multi-axis machining centers using CAM systems. The presented approaches to the selection of machining strategies, consideration of residual stock, and the use of tools with complex geometry make it possible to increase machining productivity, ensure the stability of the cutting process, and improve the quality parameters of the formed surfaces. The proposed solutions can be applied in the technological preparation of production for aircraft and space hardware, as well as in improving the methods for designing NC programs for the multi-axis milling of complex-profile products. Keywords: aerospace components, multi-axis machining, CAM systems, tool path generation, residual material, five-axis machining, surface quality, circle segment cutters