The aerospace industry is the study and development of many different types of
aircraft and space vehicles. This covers civil and military aircraft, helicopters,
sailplanes, spaceships, launch vehicles, and satellites. Moving within the Earth’s
atmosphere differs from moving on the ground. In the com/m Bible – aviation, space
travel, and defense, dependability, and sturdiness of aerospace parts are critical
considerations. The creation of geometries of aircraft parts is a complex task that
needs immense expertise. The thing is that there is no room for errors here. This
reveals how Aero-space manufacturing employs CNC machining.
Aerospace CNC Machining – An Insight
Aerospace CNC machining encompasses a process in which computer-controlled
tools produce essential components of aircraft and spacecraft. Since aircraft move
at high speed, there is a need to have a material that can endure different weather
conditions. Consequently, aerospace CNC machining is highly appreciated.
CNC stands for computer numerical control and it is a method through which
computers control the manufacture of various products without the need for
human intervention. This technology can also be used to produce parts necessary
for constructing and maintaining air and space vehicles. Consequently, there is a
need to reduce inaccuracies in the manufacturing of aircraft because an error
during manufacturing may cause disastrous results. There can be no mistakes
while executing a plan. The CNC machines make it possible to get consistent
outcomes in this case one piece or many as long as the prototype has been well-designed
Relevance of CNC in Aerospace Production
CNC machining holds a prominent position in aerospace manufacturing for several reasons:
Achieving High Precision
CNC machining enables manufacturers to produce different aircraft parts with
great precision. Most aerospace firms depend on outsourcing for certain
subassemblies. These parts have to be very precise and within very tight
tolerances so that every aspect of their production is accurate.
Aerospace CNC machining manufacturers use kits, assemblies, and components
that are essential in aerospace production. They carefully manufacture each part
to the required detail, with tolerances of 4 micrometers. In other industries,
component failures may be acceptable, but in aviation, this is not possible. Thus,
CNC machining provides the level of accuracy that is critical for safety.
Applications of Aerospace CNC Machining
CNC makes great sense to be used in several fields as it embraces a broad
category of applications of fabrication. An aircraft has millions of parts, and
therefore, requires different manufacturing techniques. Some of these methods
include sheet metal fabrication, injection molding, and some of the following;
aerospace CNC machining and 3D printing.
For instance, the best machining process is used in the 5-axis in making aircraft
components parts with difficult work. This aerospace machining method allows
simultaneous cutting, drilling, and positioning along the X, Y, Z, and linear axes.
The kind of processes that can avoid the need to reposition or reorient the part
include: What is the reason for complexity in aerospace? The answer is weight loss.
Designing a thin or complex structure while designing the part makes the weight
lesser at the same time it will not affect the strength and functionality of the part.
Aerospace CNC machining companies work on the principles of incorporating the
best design with the best workflow software and strict inspection methods. This
combination enables them to create outstanding tooling components and end-use
parts for aerospace industries. It is not possible to mention all the CNC machined
aerospace parts but a few of them are hydraulic manifolds, fuel bodies,
transmissions, landing gear, and electrical connectors.
CNC machining is essential not only for manufacturing end-use parts but also for
the research and development of the aerospace industry. This capability allows for
the creation of new parts and components to be quickly produced, and tested,
with modifications made quickly if necessary. Aerospace companies and OEMs can
turn to Feitai for CNC machined prototypes and parts in three days with tolerances
of 0.002 mm.
Aerospace CNC Machining in Aircraft
Accuracy is considered important in aircraft manufacturing, from loaded cargo airlines to fighter aircraft, or even passenger airlines. Such
accuracy requirements are required for all aircraft components, starting from the
systems’ heart to the outer cover. For example, an airplane’s engine must perform
efficiently so the plane continues to soar. This means that the engine has to
handle fuel efficiently. CNC machining is used to manufacture several vital parts
that are vital for the performance of the engines.
The cockpit also reveals important aspects of aerospace manufacturing. Small
components joined form effective guiding systems that aid planes in determining
the correct direction. These aerospace parts are made possible by CNC machining.
In addition, further refining such critical subassemblies as wings can allow for
performing safe and energy-saving flights.
Aerospace CNC Machining as Applied to Space
Travel
When thinking about space travel, NASA and SpaceX are two companies that first
pop up in our minds. These organizations construct advanced technology space
automobiles and launch automobiles for different missions. This process is greatly
aided by aerospace CNC machining. Used for building almost all parts, from small
elements up to the rocket’s body.
Designing spacecraft to withstand the realities of the space environment is
important. Accuracy is still critical in this regard. Parts have to work perfectly with
the added constraint of protecting the crew and the spacecraft. Since accuracy in
manufacturing is a requirement for these applications, CNC machining is the ideal
solution for this.
For CNC Machining Capabilities,
At Shenzhen Feitai, our engineers strictly follow the industry regulations to
constantly develop the CNC machining technology. Whether you require high or
low tolerance on your aerospace CNC parts, our team has the necessary skills to
deliver them. We pride ourselves in ensuring that our customers get the best
precision as is possible.
Aerospace CNC Machining with 5-axis CNC
CNC machining for aerospace parts has complex variations. Consequently,
employing 5-axis milling machines is quite reasonable for setting up many of these
parts. 5-axis CNC machining involves complex motion where cutting tools and
components traverse along up to five axes.
These machines allow the establishment of complex geometries in the course of
the manufacturing processes. With the advancement of the aerospace industry,
constant redesign and repositioning of components become feasible by using
5-axis CNC machining. This robust process is capable of dealing with the technical
intensity and size of aerospace parts. Manufacturers can also mill, drill, and
fabricate parts to fit the aircraft to suit high-performance requirements.
Materials Employed for Aerospace CNC
Machining
From aerospace manufacturing to the general public, the first things that may be
considered are the aircraft engine and wings, but an aircraft is made up of millions
of parts. For instance, the Boeing 747 airplane has over 6 million parts and not all
of them are made through CNC machining.
Lightweight Metals
Aluminum aerospace CNC machining
Two critical properties dictate the materials used in aerospace CNC machining:
strength and weight. Steel is a very robust material, but it has too much weight
which in many applications means lower miles per gallon and higher costs.
Therefore, aerospace industries consider only those metals that are strong as well
as lightweight such as Titanium and Aluminum alloys. These materials are easily
machined and the industry requirements are fulfilled. Titanium is about 30%
stronger than steel and is 50% lighter with high resistance to high temperatures
and corrosion. This makes it suitable for both functional and external structures of
aircraft.
Aluminum is lighter than titanium but it has only about half the strength of the
material. But it is cheaper and can be used in almost any aircraft part.
High-Performance Plastics
While it is clear that metals are used in an aircraft’s design, various interior parts
use polymer materials. These plastics are far lighter than metals which makes it
possible to produce components such as interior wall paneling, air extraction
ducts, aircraft doors, wiring conduits, bearings, and other applications such as
aircraft parts. These aerospace-grade plastics are lightweight, high strength, and
also meet the standard of fire retardant.
CNC aerospace machining is particularly brilliant in the production of stiff,
lightweight, and intricate plastics for the aerospace business. Examples are PEEK
and other high-performance polymers. Like metal fabrication, aerospace
machining guarantees accuracy which is necessary for polymer-based uses.
Aluminum and Aluminum Alloys
Aluminum is among the products with a high tensile strength, which makes it used
for the manufacture of aerospace parts and other lightweight metals. It is highly
formable, and thus can easily be machined with computer numerical control tools.
Aluminum 7075 is the most used aluminum alloy in the aerospace industry and it
mainly consists of zinc. This alloy has specifically high fatigue properties and is
employed primarily for wings, the central body, and bracing members.
Other machinable aluminum alloys include 4047 (cladding and filler), 6951 (fins),
and 6063 (structural members). In general, 6000-series alloys are easier to
machine than any other kind of alloys.
Titanium and Titanium Alloys
The aerospace industry is the major consumer of titanium alloys. This metal is
ideal for high temperatures; it is corrosive resistant and has a high
strength-to-mass ratio; therefore, used in the manufacture of aerospace products.
Titanium is employed in varying large amounts in civil and military airplanes such
as Airbus, and B787 and in trending helicopters such as F-22, and UH-60 Black
Hawk. Titanium products are discs, blades, shafts, and casings for airframes and
jet engines.
CNC machining of titanium can be complex because it is more rigid than
aluminum and results in wear and tear of the tools, and heat generation that may
cause distortion. As a result, titanium machining tends to operate at a slower RPM
and a higher chip load.
Engineering Plastics
Plastics are cheaper than metals, have low density, good resistance to impact and
vibrations, and are good seals and chemical barriers. They also have better
electrical insulation and are well-suited for prototype CNC machining. These aromatic polyetherether-ketone (PEEK), Polycarbonate, and Ultem polymers are
usually used in aerospace applications.
Plastics used in aerospace engineering can be CNC machined to form parts like
cabin interiors, tray tables, wear pads, armrests, back-lit instrument panels, valve
parts, housing, tubes, and insulation.
However, not all the engineering plastics that can be machined are used in
aerospace machining. Aircraft polymers are required to be free from toxicity,
produce minimal smoke, and have high fire resistance; hence, compliance
becomes essential.
Usual Surface Coatings for CNC Aircraft
Components
Different types of surface treatments are possible for the CNC aerospace
machined parts but not all of them can be applied to the aircraft parts. There are
four typical surface treatments known to the industry.
Anodizing
Aerospace Anodized Parts
Anodizing is done by immersing the aerospace part in a bath of electrolytes to
build up a steady layer of regular oxide on the outer skin. Two types of anodizing
are utilized in aerospace parts: Type II and Type III.
Type II anodizing gives a thin layer of a relatively finer and more ornamental
surface, yet aluminum is more vulnerable to conditions such as corroding and
wearing. Nonetheless, Type III generates a thicker protective hard coat on the
surface of the part being anodized.
Aluminum anodizing is a method that is used to protect aerospace parts from
corrosion and to increase their useful life.
Passivation
This is the process of passivation which is after treatment carried out in aerospace
CNC machining to improve the surface finish and usage. Finally, when the parts
are machined, there is always feature roughness or surface contamination that
can contribute to performance differences. Passivation solves these problems by
increasing corrosion protection and decreasing the amount of maintenance
required.
Polishing
One of the great surface treatments for aerospace parts is polishing. This is one of
the first procedures that use abrasion in a bid to provide a polished surface to
materials. It often has an uneven coarse beginning and ends up with a glossy and
polished appearance.
Besides, the process of polishing can improve the overall properties of aerospace
parts because there is a low likelihood of chips or cracks. Nonetheless, polishing
could be a tedious and expensive process.
Powder Coating
The most popular type of surface finish in metallic aerospace parts is powder
coating as it is resistant and comes in a variety of colors. Aerospace parts that
have been coated with powder do not easily get scratched or fade as is the
common trend.
Aerospace CNC Machining Parts
The aerospace industry has many uses for CNC machining, the following being a
few of the most common.
Electrical Connectors
CNC machining is crucial to the manufacture of electrical connectors in aircraft
systems. These connectors are important for the load-bearing and spacing of the
frame members.
Valve Components
Valve components are considered small but essential, and are often used in the
aerospace industry. Automated Computer Numeric Control or CNC machining
ought to be used in the manufacturing of these critical parts because it provides
precise and reliable products.
Oxygen Generation Components
CNC machining allows the production of thin-walled components for oxygen
generation systems that are resistant to high temperatures. These systems are
very important for safety in the aviation industry.
Shafts
In aeronautics, shafts are important in transmitting power. Computer numerical
control enhances the manufacture of durable shafts from heat-managing
materials.
Additional Applications
Some other areas where aerospace CNC machining is used are cabin parts, wing
ribs, fuselage components, actuators, motion controls, engine housings, landing
gear components, discs, and filter bodies.
Conclusion
The aerospace industry is reputed to have numerous quality requirements and
expectations that should be met. The specific use of aircraft requires the
production of parts with high reliability, which defines the criticality of
applications. Aerospace CNC machining offers the necessary solutions to this
sector. As one of the leading producers of aerospace manufacturing products,
Shenzhen Feitai is dedicated to providing safety and risk management services.
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