Machining Aerospace Parts

In , a routine training mission for an F-16 fighter jet took a dramatic turn. The plane, fortunately, crashed in an unpopulated area with no casualties. However, the investigation revealed a culprit: a seemingly insignificant pin inside the engine. This pin, part of a mechanism controlling airflow within the engine, fractured due to metal fatigue.

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The failure of this small, machined part caused the entire engine to fail, jeopardizing the pilot and potentially putting lives on the ground at risk. This incident serves as a stark reminder of the critical role machined parts play in aerospace. Within each of its applications in the aerospace industry, CNC machining is an often overlooked key player. Every component, from the engine housing to the landing gear, needs to be meticulously crafted to withstand extreme stresses and environmental conditions.

Applications of Aerospace CNC Machining

CNC machining is an often sought after service in manufacturing custom aerospace components for numerous applications in the industry. From complex designs to standard screws, the assembly of aerospace products and machines would not function without it. 

1. Aerospace Component Manufacturing:
   • Aircraft Structural Parts: CNC machining is used to produce critical structural components such as fuselage frames, wing spars, and landing gear parts. These components require high precision and strength to withstand the stresses of flight.
   • Engine Components: Aerospace machinists and precision machining are essential for manufacturing complex engine parts like turbine blades, housings, and fuel system components. These parts must endure high temperatures and pressures.
   • Avionics Housings: Machining aerospace parts creates precise enclosures for avionics systems, ensuring the protection and functionality of sensitive electronic components.
   • Interior Components: It is used for producing interior parts such as seat frames, overhead bins, and tray tables, focusing on both durability and aesthetic quality.
2. Tooling and Fixtures:
   • Assembly Fixtures: Machining custom fixtures for assembling various aircraft components ensures accuracy and repeatability in the assembly process.
   • Inspection Tools: CNC machines produce precise gauges and measurement tools that are used to verify the dimensions and quality of aerospace parts.
3. Prototyping and Testing:
   • Rapid Prototyping: CNC machining is utilized for creating prototypes quickly, allowing for the testing and refinement of designs before mass production.
   • Wind Tunnel Models: Scaled models for aerodynamic testing in wind tunnels are often machined to exact specifications to study airflow and performance characteristics.
4. Maintenance, Repair, and Overhaul:
   • Replacement Parts: Machining aerospace parts produces high-quality replacement parts for aircraft maintenance and repair.
   • Tooling for MRO: Custom tools and fixtures for maintenance operations are often machined to ensure precision and reliability.

Materials Used in Aerospace CNC Machining

Common materials used in aerospace components include aluminum, titanium, stainless steel, nickel, carbon fiber, ceramics, and more. Each of these materials offers strengths and weaknesses for aerospace machinists to weigh. 

1. Metals:
   • Aluminum Alloys: Widely used for their high strength-to-weight ratio, corrosion resistance, and machinability. Common alloys include , , and .
   • Titanium Alloys: Known for their excellent strength, low weight, and resistance to high temperatures, making them ideal for engine components and structural parts. Titanium 6Al-4V is particularly common.
   • Stainless Steels: Utilized for their corrosion resistance and strength, often in critical components that require durability and resistance to harsh environments.
   • Nickel Alloys (e.g., Inconel): Essential for high-temperature applications such as turbine blades and exhaust systems due to their ability to maintain strength and resist oxidation at high temperatures.
2. Composites:
   • Carbon Fiber Reinforced Polymers (CFRP): Valued for their exceptional strength-to-weight ratio and used extensively in structural components like wings and fuselage sections.
   • Glass Fiber Reinforced Polymers (GFRP): Used in areas where high strength and lightweight characteristics are required, though not as strong as CFRP.
3. Specialty Materials:
   • Ceramics: Employed in specific high-temperature applications such as heat shields and some engine components due to their ability to withstand extreme temperatures and wear.
   • Magnesium Alloys: Used for certain components where reducing weight is crucial, offering a good balance between weight and strength but with some limitations in corrosion resistance.

Machining aerospace parts is integral to manufacturing high-precision, high-strength components essential for aircraft performance and safety. It encompasses a wide range of applications from structural parts to engine components, and utilizes advanced materials like aluminum, titanium, and composite materials to meet the demanding requirements of the aerospace industry. Choosing a trusted aerospace machinist is your duty as a manufacturer.

How is CNC Used in The Aerospace Industry? 

CNC technology has been a key provider of aerospace components over the last 60 years. However, this was not the case early on for the industry. It is hard to mention the history of aerospace without mentioning the Wright Brothers and the historic flight back in . The sustained flight was just a glimpse of what was to become of a very robust industry. The early technology had limitations for an aerospace company back then. The planes were made mostly of wood and fabric. This took the efforts of very skilled craftsmen, time, and ingenuity to produce aircraft parts. These were not what we would call today's precision aerospace parts, but remarkable, nonetheless in the quality they were able to achieve. As progress was made for better aerodynamics, prolonged flight, and overall performance, it was clear that changes were going to be needed. World War II pushed all industries to create not only better designs of planes, firearms, armor, but also new types of bolts, screws, nuts, fasteners, engines, handles, levers and just about everything you can think of. As new engineering breakthroughs emerged, the growth required new materials to be developed and machined. This era, though tragic, also would propel the world into higher levels of mass production with precision. Without these advances we would not have the level of technology we take so much for granted. When the transition of wood to metals like aluminum took place, this was a societal breakthrough. Not only would all transportation change, but the world economy's world see growth unlike in any previous millennia. The key was a way to manufacture the needed precision that the advancing aerospace industry would require. CNC technology would be that solution. CNC or computer numeric control are manufacturing methods supporting almost all industries as well as aerospace. This industry has greatly advanced with computer technology and seems to have no limitation when science and industry ask for support. 

CNC technology encompasses multiple methods to produce precision aerospace components. There are three main materials used by the aerospace industry that CNC manufactures process: 

• Aluminum Alloys:  Used widely in aerospace manufacturing. It has an excellent strength-to-weight ratio and machinability. It is used in airframes and other body structures. 
• Titanium Alloys:  Titanium has superior strength and fatigue resistance and is the top choice for high-stress components like landing gear and jet engine parts. 
• Steel Alloys: Steel can be used for engine mounts, and other parts requiring exceptional strength. Steel is heavier than aluminum and titanium so specific needs and cost considerations warrant this material's use. 

Aerospace machinists will use different methods to manufacture precision parts. Examples of these are:  

• CNC Drilling: Very precise holes for rivets and fuselage panels. For holes in brackets, frames, and engine parts. 
• CNC Turning: CNC turning uses lathes to create cylindrical shapes like axels, shafts, bushings, and pins, landing gear parts and engine components. 
• CNC Threading: Parts manufacturers use threading to properly secure connections and fasten down assembled components and systems. 
• CNC Laser Cutting: Used to cut precision parts that have structural uses like frames and brackets. Versatile in developing R&D parts as well. 
• CNC Waterjet: This technology eliminates ant heat affected zones or HAZ, that can occur with other methods machining aerospace parts. Great for cutting engine components, structural and other complex and critical parts.  

A precision aerospace company will use or work in partnership with qualified CNC technology professionals. The stringent requirements asked for each project are for the public's safety. Aerospace components are a result of many years of advances in technology, but also advances in science and engineering. As progress is made so does the need to bring new ideas and concepts into reality by a sustained and reliable manufacturing solution such as CNC machining. 

Worth over $800 billion, the global aerospace industry is ripe with innovation. This industry is consistently at the cutting edge of new manufacturing practices and technologies. Aerospace CNC machining is now one of the most critical components of the industry. The reason for this is not far-fetched.

One of the most important factors when producing parts for aircraft or related systems is, of course, safety. Regardless of the aerospace project you are working on; every aircraft component must meet the highest industry standards. There is no room for human error in the production and assembly of an aircraft. From the smallest interior detail to the plane's exterior, any flaws or inconsistencies can have devastating effects.

The extremely high level of precision needed within the aerospace industry makes CNC machining a suitable manufacturing process for the sector. The capability of this process to achieve very tight tolerances for metal and plastic parts allows it to offer robust solutions in the industry. This article provides you with a complete guide to aerospace machining and its importance.

What is Aerospace CNC Machining?

This CNC machining process involves creating CNC machining aerospace parts to assemble and maintain aircraft and space shuttles. Aerospace CNC machining companies use kits, components, and assemblies which are essential for crafts used in the aerospace industry.

Aircraft parts, ranging from bushings, hinges, clamps, or other custom parts, need to come with high-quality materials. This is to ensure that these aircraft components function properly without involving any form of danger. This is why Titanium and Kovar are popular as the most used metals for aerospace components. Other materials may include aluminum, stainless steel, copper, bronze, and some types of plastic.

Importance of Precision in the Aerospace Industry

Precision machining is a vital aspect of the aerospace industry. This industry has loads of high production standards for CNC machining aerospace parts and more stringent safety controls.

Unlike other industries, the aerospace industry requires that dimensions, tolerances, and performance are the tightest and highest possible for every part. This is to ensure that these parts do not fail in flight.

A single faulty or imperfect component can cause a loss of thousands of dollars in aircraft and space stations. Furthermore, poor production techniques often lead to huge safety risks to end-users. This is why aerospace machining companies work hard to meet all of these requirements. At the same time, they have to ensure that they produce aircraft quickly enough to meet market demands.

Using state-of-the-art CNC machining equipment, qualified manufacturing services such as RapidDirect can produce aerospace prototypes and end-use components for aerospace companies. Working with aerospace-grade metals and plastics, CNC machine systems can reach tolerances up to 0.002 mm. Further, sophisticated post-processing and inspection systems can ensure that finished aerospace prototypes and parts are exactly up to standards.

Applications of Aerospace CNC Machining

There are so many applications of CNC machining across different industries. An aircraft comes with millions of components. Therefore, there are many manufacturing processes involved in their production. These processes range from sheet metal fabrication and injection molding to advanced manufacturing processes like aerospace CNC machining and 3D printing.

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For example, 5-axis machining helps to produce complex aircraft components. This aerospace machining process allows for parts to be milled, drilled, and manipulated along the X, Y, Z, and linear axes. These processes occur simultaneously without having to reconfigure or fixture the part. Why is complexity an asset in the aerospace sector? In short: weight. Producing parts with a partially hollowed out or complex geometry can reduce its weight. This action is possible without sacrificing quality or performance.

Aerospace CNC machining companies pair sophisticated design with workflow software and state-of-the-art inspection processes. This helps the companies to produce end-use parts and high-quality tooling components for aerospace manufacturers. There are several CNC machining aerospace parts produced by CNC machining, and it will be impossible to list all of them. However, some significant examples include hydraulic manifolds, transmissions, fuel bodies, landing gear, electrical connectors, housings, and more.

CNC machining doesn't only have an important role in the production of aircraft end-use parts. It also plays a vital part in aerospace R&D. This role enables aerospace companies to rapidly iterate new component designs, test them and, if needed, edit them. Aerospace machining companies such as RapidDirect can work with aerospace companies and OEMs. This will help deliver CNC machined prototypes and parts within as little as three days with tolerances down to 0.002 mm.

Aerospace CNC Machining Use in Aviation

Whether it is cargo planes, fighter jets, or passenger airlines, accuracy is an important component of aircraft construction. These accuracy requirements extend to every part of an aircraft's production. It does not leave out anything, be it the innermost layer or the outer shell. For example, an airplane's engine needs to keep it in the air for as long as it is in flight. As an implication, the engine must adequately process and use fuel. CNC machining helps to make some of the seemingly insignificant parts vital to the engine's running.

When you also consider the cockpit, you will notice the importance of aerospace machining. Some small, connected components form a navigational system that helps a plane move from one point to another. CNC machining can help create these CNC machining aerospace parts. Finetuning and tweaking critical parts such as the plane's wings can also ensure a safe and efficient flight.

Aerospace CNC Machining Use in Space Travel

When thinking of space travel, companies like NASA and SpaceX are the first to come to your mind. These companies responsibly design and manufacture the most technologically advanced spacecraft and rockets for different missions. However, aircraft CNC machining played essential roles in their ability to do this. This process is critical to manufacturing the most minute components up to the rocket's body design.

As you know, it is important to build spacecraft to withstand life in space. Precision comes to play again here. Parts do not only have to work properly, but they also need to ensure the safe operation of the spacecraft. This ensures the protection of the crew and the spacecraft itself. Since precision manufacturing is the focus word in CNC machining, this process is the way to go.

RapidDirect Aerospace CNC Machining Capabilities

At RapidDirect, our engineers meet the stringiest of industry standards to revolutionize the CNC machining process continually. Regardless of the tolerances you need for your CNC machining aerospace parts, our experts have the knowledge and experience to handle them. We have an excellent record for providing our customers with the highest possible precision.

When other CNC machining companies view your aerospace machining requirements as impossible to achieve, RapidDirect always expects your call. We are ready to work with you on every detail to ensure that the end product fits your unique requirements. Upload your design file today, and our tech-driven platform will generate quotes for you within seconds.

Aerospace Machining with 5 Axis CNC

CNC machining aerospace parts are complex, and they come in variations. Therefore, it makes sense to configure many of these parts with 5 axis milling machines. 5 axis CNC machining involves the operation of a machine using highly accurate CNC. This process moves cutting tools and parts across up to 5 axes at the same time.

The setup for the machine enables complex geometries. Since the aerospace industry continues to evolve, continuous reconfiguration and adaptation of parts are possible with 5 axis CNC machining. Generally, this robust process can cope better with the technicality and scope of aerospace components. Therefore, engineers can mill, drill, or manufacture them to the desired specifications of the aircraft. In addition, 5 axis machines meet the high-performance standards of aircraft CNC machining.

Materials Used in Aerospace CNC Machining

Although it is common to immediately think of an aircraft's engine or wings when talking about aerospace manufacturing, millions of parts make up an aircraft. For example, the Boeing 747 comes with over 6 million components. Evidently, not all the parts are produced using CNC machining.

However, among those that are, there are several materials used in an aircraft assembly.

Lightweight Metals

Two key properties dictate the CNC machining materials used by aerospace companies. These properties are strength and weight. Although considered strong, metals such as steel are not ideal for most parts. This is because they are incredibly heavy, leading to less fuel-efficient (and thus more expensive) planes.

The aerospace industry, therefore, looks at strong and lightweight metals such as titanium and aluminum alloys. Both of these metal materials used in CNC machining are easy to work with. Titanium, for instance, is roughly 30% stronger and 50% lighter than steel. It also boasts excellent resistance to high temperatures and corrosion. Thus, it is ideal for functional aircraft components and external parts.

Aluminum, for its part, is lighter than titanium but only about half as strong. The highly machinable metal is, however, more cost-effective than titanium. It is also well-suited for a wide range of aircraft components.

High-Performance Plastics

Although metal components boast more applications in an aircraft's functional structures, many interior components come from polymer-based materials. These materials are significantly more lightweight than metals. They help produce parts such as interior wall panels, ventilation ducts, aircraft doors, wiring conduits, bearings, and more. They are aerospace-grade plastics that are lightweight, strong, and meet aerospace fire retardant regulations.

Aerospace CNC Machining creates strong, lightweight, and complex plastic parts for the aerospace industry. Making these parts include such materials as PEEK and other high-performance polymers. Similar to working with metals, aerospace machining offers the high precision needed for polymer-based aerospace applications.

Conclusion

The aerospace industry is known for its high-quality requirements and industry standards. The delicacy of the application of aircraft also makes it vital to produce high-quality parts. Aerospace CNC machining offers the required solution needed by the industry. With attention to safety and risk management, RapidDirect is ready to cater to your aerospace manufacturing needs.

If you want to learn more, please visit our website Aerospace Machined Parts.