Aerospace Machining Processes

What Is Aerospace Machining Technology?

Machining aerospace parts by turning raw materials like titanium, aluminum and nickel alloys is part of the art and science that aerospace machining has become. Creating intricate components that allow commercial airlines to take us to worldwide destinations and explore beyond Earth with advanced spacecraft, is why there is a great relationship between high precision CNC technology and the aerospace industry. These technologies, coupled with the use of high-performance materials enable the creation of aerospace components that can withstand the extreme conditions of flight, from the blistering cold of space to the intense heat of jet engines. Development of components and providing production volume support is not an easy task. The aerospace industry is a complex ecosystem where innovation, precision, and public safety are paramount. The process of developing a new component typically begins with identifying a need or a potential improvement. Engineers and designers then conceptualize the component, often using advanced software for computer-aided design (CAD) and analysis. Once a design is finalized, prototypes are created. These prototypes undergo rigorous testing under simulated and real-world conditions including structural testing, fatigue testing, and environmental testing to ensure the component can withstand the extreme pressures and temperatures of flight. If the component passes these tests, the industry moves to the production phase. This is where contract manufacturers like CNC technology companies play a crucial role. These manufacturers possess the specialized equipment and expertise to produce components with the required precision and quality.  We see in movies the advanced future methods of transportation and they do look extremely complex. However, we do forget the immensely complex and advanced systems we already have. A modern jetliner includes a staggering number of aerospace components that it takes to manufacture just one. A Boeing 747 for example, is made up of about 6 million parts, so the complexity is here already. To take the concepts of designers and engineers off the ground machining aerospace parts includes methods that can meet the high standards required. Some of the often-used machining methods are:

CNC Machining Technology

• Materials: Aluminum alloys (like 7075 for its strength), titanium alloys (for their high strength-to-weight ratio), and stainless steel (for corrosion resistance) are commonly used.

• 5-Axis Milling: Offers unparalleled flexibility, allowing for complex shapes and intricate details in a single setup. Ideal for turbine blades, fuselage parts, and aero foil panels.
• Turning: Primarily used for cylindrical components like shafts, axles, and rotors. High precision is essential for ensuring proper fit and function.
• Milling: Versatile for creating various shapes and profiles. Used for a wide range of components, from engine parts to structural elements.
• Drilling: Essential for creating holes of different sizes and depths. Crucial for assembly and fluid flow systems.

Specialized CNC Machining Methods

• High-Speed Machining (HSM): Enables rapid material removal with exceptional surface finish, ideal for intricate and complex parts.
• Hard Milling: Used for machining hardened materials like titanium and nickel alloys, ensuring durability and longevity of components.
• EDM (Electrical Discharge Machining): For creating complex shapes and intricate features in hard-to-machine materials.

Note: The specific method chosen depends on factors such as material, component geometry, tolerances, and production volume. Often, a combination of these methods is used to create a finished part.

The relationship between the aerospace industry and a precision aerospace company is characterized by close collaboration. Aerospace OEM’s provide detailed specifications, materials, and quality standards, while the precision aerospace company leverages their technical capabilities to produce the components efficiently. The process often involves multiple iterations of design and manufacturing as engineers fine-tune the component based on testing results. Throughout the entire process, stringent quality control measures are in place through certifications like AS9100 and ISO 9001. To meet the demands of their clients, aerospace machinists adhere strictly to these quality standards. This ensures that every component meets the highest industry standards, as even a minor defect can have catastrophic consequences.