High-Speed Machining for Aerospace Materials

High-speed machining (HSM) is a common technique used in the aerospace industry to improve efficiency, achieve high precision, and provide an ability to handle challenging materials effectively. In simple words, it is characterized by high machining speeds and significant performance improvements. Some of the most widespread aerospace alloys such as AA7050, AA7075, Ti-6Al-4V, and Inconel 718 are machined using HSM. However, despite its benefits, there are still various challenges associated with the increased performance. Such challenges include reducing tool wear, managing machining temperatures, enhancing surface quality, improving the predictions of the machining behavior, optimizing the machining parameters, and increasing sustainability. Recent research in aluminum alloys has primarily focused on parameter optimization, improving numerical simulations, advances in cooling methods, and process predictions. In the recent studies involving difficult-to-cut alloys Ti-6Al-4V and Inconel 718, the focus was more on tool wear, cooling methods, choice of tools and coatings, machining mechanisms and their predictions, and the application of new techniques such as vibration and hybrid machining. This chapter provides an overview of HSM technology and the aforementioned recent developments in its utilization in the aerospace industry.