At present, CNC machining is widely used in various fields. Especially in aerospace manufacturing, the precision and quality of parts are required to be extremely high. Therefore CNC machining is indispensable in aerospace manufacturing. It has high precision. It can machine complex shapes quickly. In addition, it is adaptable to many materials. It cuts manpower and errors. It improves material use. These traits make it a core technology in aerospace manufacturing. CNC machining enables aerospace manufacturing to produce high-quality parts. The parts meet strict standards, ensuring aircraft safety and performance. Yonglihao Machinery has much experience and expertise in CNC machining. This article will show you how CNC machining is changing aerospace manufacturing. You will learn something from reading this paragraph. Now let’s get started!
Table of Contents
What Is CNC Machining?
CNC machining is a manufacturing method. In it, a computer controls the movement of the machine tool and the machining process. It uses pre-programmed software and code to control the movement of the machine tool. The tool performs cutting, drilling, milling, turning, and other operations to create accurate parts.
CAD software creates a 3D model and design drawings of the part. Then, CAM software makes machining paths and turns them into G-code or M-code. These are instructions that the CNC machine tool can understand and execute. Finally, the program code is entered into the control system of the CNC machine tool. The instructions are run to complete the machining of the material, such as milling, turning, and drilling.
CNC machining has many machining advantages, such as high precision and high efficiency. It is widely used in aerospace, the automotive industry, and medical devices. It provides key support for the development of modern manufacturing.
What Materials Are Used in Aerospace Machining?
Aerospace machining is a highly adaptable process. However, not every metal or plastic is suitable for manufacturing aircraft parts. The following materials are used for manufacturing aircraft parts.
Aluminum and Aluminum Alloys
Aluminum is one of the most commonly used metals for manufacturing aircraft parts. This is because it is lightweight and has high tensile strength. Aluminum is also easy to machine on CNC machines because it is very easy to shape.
The main alloying element of 7075 aluminum is zinc, and it is the most commonly used CNC-machined aluminum alloy in the aerospace industry. It has good fatigue strength. Many parts of the wings, fuselage, and support systems are made of this material.
In addition, aluminum alloys 4047, 6951, and 6063 are also commonly used aluminum alloy grades. Therefore, it is generally considered that the 6000 series alloys are easier to machine than other alloys.
Titanium and Titanium Alloys
Titanium is the metal most widely used in the aerospace industry worldwide. The metal is resistant to high temperatures, does not rust, is lightweight, and has high strength. Titanium is therefore now commonly used in the construction of spacecraft. Both commercial and military aircraft require large quantities of the material for different components. Titanium is used to make disks, blades, shafts, and covers for jet engines and airframes.
Since titanium is harder than aluminum, it can be more difficult to machine numerically controlled. This can lead to tool wear and heat build-up, which can bend the material. To machine titanium aircraft parts, machine tools need to run at lower speeds and produce more swarf.
Engineering Plastics
Engineering plastics can be an ideal alternative to metal. They are very light and do not break easily when impacted or vibrated. They also have the advantage of being airtight and not reacting with chemicals. On the other hand, they prevent the flow of electricity better than metal and are therefore ideal for prototyping CNC machining. Polymers such as PEEK, polycarbonate, and Ultem are very robust and can make for machining aircraft.
What Are the Benefits of Using CNC to Machine Aerospace Parts?
CNC machining improves the production process and makes aerospace components better. This section discusses the different benefits of CNC machining, focusing on how it helps to create components that are lightweight, flawless, and very precise.
Lightweight Components
One of the biggest advantages of CNC machining for aircraft manufacturers is the ability to create very lightweight components. Aerospace specialists are always looking for ways to make components lighter. This reduces fuel consumption and improves performance.
Computer numerical control (CNC) machining can produce components with complex shapes. These components are not only strong but also much lighter than those produced using traditional methods. CNC machining uses materials such as titanium and aluminum, which are known for their high strength-to-weight ratio. They ensure that aerospace components perform perfectly without sacrificing durability.
Minimizing Part Errors
The precision of CNC machining is important for ensuring that errors are minimized when manufacturing aircraft parts. Modern CNC machines can repeatedly manufacture the same product with very small tolerances. This is important in the aircraft industry, where every micron counts.
This level of precision reduces the likelihood of parts breaking, making aircraft parts safer and more reliable. CNC technology also reduces human error by simplifying the machining process. It ensures that each part is manufactured exactly to specification.
Accuracy and Precision
In the aerospace industry, unrivaled accuracy and precision are essential. This is usually only possible with CNC machining. CNC machining is perfectly suited to the aerospace industry. It meets stringent manufacturing standards and controls tolerances to within a few microns.
This level of precision is essential for components that are subjected to harsh conditions and pressures. This ensures that they work efficiently in vital areas such as engines and the structure of spacecraft and aircraft.
Consistency
Another benefit of CNC machining is that it makes the part manufacturing process more consistent. Every part produced on a CNC machine is made with the same precision and specifications. This reduces the variation that can affect the performance of aerospace parts.
Maintaining the quality and reliability of parts from batch to batch depends on this consistency. It helps the aircraft industry meet its need for uniformity in a high-volume production environment.
Efficiency
In aircraft manufacturing, CNC machining stands out due to its outstanding performance. The inclusion of CNC machines makes it easier to automate production processes. The machines can be run continuously without the problems associated with manual operation. This not only speeds up the manufacturing process, it also makes optimum use of resources and supplies.
CNC machines are so precise that they ensure minimal scrap rates for each part. This makes the most of valuable materials such as titanium and aluminum alloys. This efficiency is important in an area where time and resource management have a direct impact on practical and financial success.
Reducing Manufacturing Costs
The use of CNC machining in aircraft manufacturing can significantly reduce costs. CNC machines reduce workloads by automating many tasks that used to be done manually. Workloads are a costly part of any business.
In addition, the high precision of CNC machining reduces material waste and errors that can lead to expensive repairs or scrapping. Fast, accurate manufacturing of parts also reduces time to market. This reduces overhead costs and increases profits for aircraft manufacturing companies.
Machining Complex Shapes
In the aviation business, the ability of CNC machines to machine parts with complex shapes is very useful. When manufacturing aviation parts that require complex designs, precise dimensions, and tolerances, it is difficult to achieve using standard manufacturing methods. CNC machines, especially five-axis CNC machines, can manufacture very fine and complex shapes. And this is exactly what aviation parts require. This skill makes it possible to manufacture more advanced and efficient aviation systems. Therefore, CNC machining helps improve the overall performance and usability of the aircraft.
Speed
Another important advantage of CNC machining is speed. Compared to traditional methods, CNC machining can produce parts much more quickly. This is very important in the aerospace industry. Meeting project deadlines can mean the difference between success and failure.
CNC machines can quickly manufacture many things, so prototypes can produced more quickly. This allows flight engineers to test and improve designs more quickly. This reduces the time it takes to develop new products and get them to market more quickly. This also allows companies in the fast-moving aerospace industry to stay ahead of the curve.
Precision and Efficiency in CNC Machining
The aerospace manufacturing industry has very high requirements for part accuracy and efficiency. They are crucial for aircraft safety and reliability. CNC machining is vital in aerospace manufacturing. This is due to its high accuracy and efficiency.
High Precision of CNC Machining
First, CNC machining uses computer software to control the machine tool. This allows for high-precision machining. The dimensional accuracy can reach the micron level. It meets the strict requirements of aerospace equipment for part accuracy. Second, CNC machining reduces human error. It does this by automating manufacturing. This ensures the stability and consistency of machining quality. Finally, the tech is highly flexible. It can process many complex part shapes. It meets the varied needs of aerospace design.
High Efficiency of CNC Machining
Now, CNC machining is automatic. It is done through computer control. This greatly cuts manual time and raises efficiency. After programming once, CNC machine tools can run without frequent tool changes or equipment adjustments. They achieve high production efficiency. Also, CNC machining enables fast cutting and synchronized multi-axis motion. This greatly reduces machining cycle times. This enables aerospace companies to complete production tasks in a shorter period of time to meet market demand. At the same time, CNC machines can automate production. They reduce the number of workers. This cuts costs and improves the on-time delivery rate of products.
Material Diversity and Realization of Complex Geometries
The aerospace industry must handle many strong, light materials. It must also process parts with complex shapes. This is to meet the safety and performance needs of aircraft.
Diversity of Processed Materials
Processing of high-strength alloys: High-strength alloys, like titanium and high-temperature alloys, have excellent strength and heat resistance. CNC machining can cut and mold these materials accurately. It does this to meet the demands of making aerospace components for extreme conditions.
Machining of composites: Machining of composites is the machining of materials like carbon fiber-reinforced composites (CFRP) and glass fiber-reinforced composites (GFRP). CNC machining allows for precise cutting, drilling, and trimming of composites. It lets us make complex shapes and structures using specific tools and processes.
Machining of Aluminum Alloys: Machining of Aluminum Alloys is widely used due to its lightweight and good mechanical properties. CNC machining enables high precision. It can make thin-walled, complex parts from aluminum alloys.
Machining of Complex Geometries
CNC machining uses 5-axis machine tools. It can precisely machine complex surfaces and curves in space. Five-axis linkage lets the tool contact the workpiece from many angles. This reduces the need for tool changes and clamping errors. It improves machining accuracy and efficiency.
We use advanced CAM (Computer Aided Manufacturing) software. It is used for multi-axis programming. It generates machining paths for complex parts. Simulate and optimize the machining path. This will ensure the path is feasible and efficient.
By optimizing the tool’s path planning, we reduce empty strokes and repetitive cutting. This boosts machining speed. It also ensures the needed precision for high-quality cutting of complex shapes.
Main Applications of CNC Machining in the Aerospace Industry
Aircraft structural parts manufacturing
Many aircraft parts need to be both strong and light. So, CNC machining is one method used to meet these needs. For example, consider wing components. They are often made of aluminum or titanium alloys. CNC machining lets us control their size and shape precisely. This ensures the reliability and stability of these critical parts. There are also fuselage frames and connectors. They are the main load-bearing and connecting structures of airplanes. Using CNC multi-axis machining, complex shapes, and high-precision dimensions can be efficiently processed.
Machining of Aero-engine Components
The blades in aero engines are usually made of high-temperature alloys. These include turbine blades and compressor blades. The complex blade geometry is precisely machined using CNC machining technology, which ensures its performance and lifespan in high-temperature, high-pressure environments.
Machining of Spacecraft Components
Rocket motor components such as combustion chambers and nozzles. These components can be subject to high temperatures, high pressures, and intense thermal shocks. CNC machining enables complex shapes. It also allows precise control of dimensions. This control ensures the performance and safety of rocket motors. In addition, satellite structures include frames, side panels, antenna mounts, and many other spacecraft components. CNC machining can make lightweight, strong, and complex shapes for satellite structures. This ensures the stability and reliability of satellites in space.
Aerospace Mold Manufacturing
CNC technology is used to process parts. But, in aerospace, some parts can’t be directly made with CNC. They need to use mold die-casting. Examples include engine blocks and transmission cases. CNC machining can create complex mold cavities to meet the forming requirements of metal parts. It can use molds to manufacture parts that meet technical requirements.
CNC machining quality control
Quality control before processing
On the one hand, do a good job of material and tool selection and control. Choose high-quality materials that meet aerospace industry standards. Examples include aluminum alloys, titanium alloys, stainless steel, and composites. We inspect incoming raw materials for quality. This includes analyzing their chemical composition and testing their mechanical properties. The goal is to ensure the material meets the processing requirements. When selecting machining tools, choose suitable high-performance tools to ensure the stability and precision of the machining process. But, the parts have certain characteristics and requirements. So, the process route and cutting parameters should fit them.
Quality control during machining
We monitor the operating parameters of the machine tool in real time. These include cutting speed, feed rate, and cutting force. We use them to check the stability and reasonableness of the machining process. We make timely adjustments and optimizations based on the results of the first part’s machining. Adopt on-line measurement system, such as on-machine measurement probe, to carry out real-time measurement of the parts under processing, and discover the dimensional deviation in time and make adjustments. In production, the products are sampled at a certain percentage. This is to check the consistency and stability of the processing quality.
Quality control after machining
After processing, measure the parts using equipment that fits their size and accuracy. Use the equipment the drawings specify. For example, the use of CMMs on machined parts. They test size and shape to ensure the parts meet the design requirements. After the inspection, the results are evaluated. This is to ensure that all parts meet aerospace industry standards and requirements.
Conclusion
Technology is progressing. CNC machining will have a broader role in making things for aerospace. CNC machining has excellent advantages. It is good for high precision and high volume. Yonglihao Machinery also has a lot of machining experience and high precision CNC equipment in this area. We can provide expert solutions and services. If you have needs and projects in CNC machining, please contact us. Yonglihao Machinery will give you one-on-one professional services.
FAQ
What is CNC machining?
CNC machining is one type of manufacturing method. It uses computer-controlled machine tools to make parts. It controls the motion and machining of the machine tool through programming. This achieves high precision and efficiency in making parts.
What are the main advantages of CNC machining in aerospace manufacturing?
CNC machining is used in aerospace manufacturing. It has the advantages of high precision and the ability to machine complex shapes. In addition, it can work with a wide range of materials. It is also fast and produces good surface quality.
How can CNC machining improve productivity?
CNC machining can improve productivity. This is done by optimizing processes, machine settings, programs, and operator skills.