An insight into aerospace precision machining
Through aerospace precision machining, flanges, couplings, seat frames, aircraft tray tables, clamshells and hundreds of parts can now be mass produced. In order to ensure accuracy and precision in machining, CNC technology is used to ensure that components meet the same strict criteria and standards. CNC turning lathes, spindles and horizontal and vertical milling centers are being used in the production of missile components, guidance fins and aerospace couplers. The vast range of aerospace components can be machined precisely from a variety of metals that include titanium, Inconel, cold roll steel and aluminum. More recently, aerospace parts are being made with carbon/epoxy composites and laminates for strength, light weight and electrical resistance. In the aerospace industry, there is no room for human error that is why aerospace precision machining is being used on the components.
Importance of 5-axis machining
One of the most advance CNC machines is the 5-axis milling machines that have the capability to perform multiple tasks with a single setup. In conventional machining techniques, machining of parts requires multiple setups on multiple machines. Not only does conventional machining require setups, there is part transfer and inspection for each step which consumes various resources and wastes a lot of time. When done correctly, 5-axis machining eliminates multiple setups, part transfer and part handling. Human error is also eliminated because handling and setups are greatly reduced. 5-axis machining provides the precision required by the aerospace industry because it eliminates out-of-tolerance error accumulation that results from multiple setups and manual handling. Along with lower cost per part, there is the ability to maintain parts conformity even with future runs.
Another advantage of 5-axis milling is that shorter cutting tools can be used since the head can be lowered towards the job and the cutter can be oriented towards the surface. As a result, there is higher cutting speed without putting excessive load on the cutter. This increases tool life and helps avoid breakage. When shorter cutters are used, there is a reduction in the vibration of the tool. Vibration often results when machining deep cores or cavities with 3-axis machines. When vibration is reduced, there is higher quality surface finish that eliminates the need for time consuming hand finishing.
When 5-axis milling machines are used, there is the ability to machine extremely complex parts from a solid material that would otherwise require casting. While casting is the better choice for short runs and prototypes, 5-axis machining is much quicker and less expensive. While it may seem trivial in comparison to machining complex parts, drilling a series of holes with different compound angles is completed much more quickly with 5-axis machining.