During machining, if the tool is severely damaged, it will usually damage the machined part, and sometimes even damage the machine. Aeronautical parts usually have a complex shape and are made of valuable materials. The processing of these parts requires a lot of man-hours. Therefore, if the workpiece scrap, both in terms of raw material costs, or in the processing of added value, will cause huge losses.
In the aerospace industry, single piece of small batch processing is not uncommon, so damage to a workpiece will cause great damage to the production efficiency. Since the failure of an aircraft component can lead to disastrous consequences, the mechanism for compliance control and risk reduction in the aeronautical industry makes it easier to reprocess damaged workpieces than in other industries. Damage to the workpiece or machine tool caused by tool breakage can seriously affect the manufacturer’s profitability and customer satisfaction.
Many of the dedicated machine tools used in the aerospace industry are responsible for critical processing tasks. Because these machines are expensive and long processing time, they are likely to be “bottlenecks” of the manufacturer, and if these machines are damaged due to tool breakage, they will have a significant impact on the company’s production capacity.
In cutting, there are many reasons that can cause damage to the tool, but there is not a solution to ensure that 100% of the detection or completely avoid the occurrence of tool damage. A specially developed tool breakage recovery cycle program can save artifacts and production losses. In view of the machine tools, material costs and the value added of the products in the aviation industry, it is necessary to develop different levels of tool breakage prevention and detection strategies in order to protect the investment of enterprises.
In the aerospace industry, the value of the workpiece and the type of material being processed require that the best quality tool be used in most of the machining. However, even if the best tool is used, if an incorrect process parameter is used for a particular tool or process during machining, or if the operator has made a mistake during the tool installation or adjustment, it may still cause damage to the tool.