Introduction: Metal processing online reporters attended the annual meeting of China's steam turbine industry for two consecutive years in 2011 and 2012. Now, we are compiling the issues raised by various experts during those meetings. Some of these are specific enterprise cases that have been discussed and partially resolved, while others represent broader challenges within the industry, which we hope will draw attention from tooling experts. Dong Liu Liu Guangyao: How to improve the drilling efficiency of composite plates? There are titanium and stainless steel composite plates that require thousands of holes. Especially with stainless steel composites, imported Kyocera drills can solve the problem to a certain extent, but the efficiency still needs improvement. Drilling through stacked plates is a major challenge. Dongqi spent two months conducting drilling tests on stacked plates because the gap between them is large—some reaching up to 2.5mm—and this gap changes during the cutting process, making it easy for the drill bit to break. With Kyocera’s magic drill, the bit can be replaced, and each one can drill over 300 holes to meet the target. However, the cost is high, and there is still room for improvement. How to make stainless steel parts easier to chip during turning? When machining rotating blades on a turning-milling machine, the material is stainless steel, which is relatively soft and does not break easily into chips during turning. This significantly limits processing efficiency. How to improve the machining efficiency of superalloys? For high-temperature alloys (up to 600°C), operations like turning, milling, and threading are mainly done using carbide tools. Strath’s tools perform better than others, but efficiency still needs to be improved. I have tried CBN and ceramic tools, but these tools—especially ceramics—require high rigidity in the workpiece. So, how can we further enhance the efficiency of superalloy machining? How to reduce surface roughness during low-speed turning? A high cutting speed is typically needed to achieve good surface quality, but some workpieces, such as gas turbine cylinders, cannot be rotated at high speeds, leading to unsatisfactory surface roughness. How can we improve surface quality? Adding grinding equipment to the vertical lathe would affect the lathe due to poor sealing. Using a rolling method could cause deformation due to high pressure. Therefore, it would be ideal to solve the issue directly through tooling improvements, such as optimizing the tool angle.
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