5 challenges in machining aeronautical parts and components: solutions

Introduction

Problems in the production of various aerospace parts can have serious consequences and often wreak havoc. In short, aerospace components and parts have to work perfectly every time. Whether it’s gears or mounts, every component must turn and fit in its place without unexpected problems.

When it comes to the manufacturing process, using the right materials and tools can make all the difference. Today, the manufacture of aerospace components must have tight tolerances and precision fits. In fact, there’s no room for quality when it comes to modern aerospace components.

After all, high quality is linked to lead time and overall cost. No wonder CNC machining has become an integral part of a wide range of aerospace applications. One of the advantages of automated CNC machining is that it minimizes potential human error and guarantees high-precision manufacturing.

What components can you manufacture with CNC machining?

From modern aircraft to engines and landing gear, manufacturers use CNC machining to create aerospace parts. Manufacturers also use CNC machining to produce structural and moving parts such as bulkheads, airframes, fuselages, shafts and gears. But whether it’s torque rods, mounts, turbines or compressors, there’s a long list of components you can produce with CNC machining.

Common challenges (and solutions) in machining aerospace parts

Let’s take a look at five different challenges producers often face when machining aerospace components, and their solutions:

Getting the “right” material

In the aerospace industry, it takes continuous effort to obtain and maintain the most suitable material properties. Engineers often struggle to obtain the particular material properties to create specific aerospace applications. In the heat treatment process alone, manufacturers face significant challenges.

The solution is to invest in tools made from harder materials such as titanium, and heat treat them before machining. This is the best way to mitigate these problems and ensure an optimized heat treatment process. On the other hand, engineers often have to worry about sourcing the “right” materials. From superalloys to specialty plastics, focus on the material that takes the least time and costs the least to manufacture the part.

Component size

One of the limitations of CNC machining of aerospace parts is the size of the component. Technically, component size is a geometrical challenge. As a general rule, large aircraft require large assemblies of hundreds and thousands of parts.

Since machine frames are only a few feet long, this creates additional space problems for structural components. This makes it difficult to find a suitable supplier capable of handling large parts. You can solve this problem by finding a supplier who handles large parts and operates huge CNC machines.

Machining large components in thin walls

Components such as compressor housings or motors often have large internal cavities. This leads to a time-consuming process that creates endless amounts of waste. Not to mention the fact that it creates residual stresses on the component. Ultimately, these stresses can turn into warpage or deformation, which in turn creates more problems when you’re dealing with tight tolerances.

Solving complex geometries

Because aerospace parts are manufactured using 3D printing to meet unique requirements, they often feature complex geometries. The trick is to minimize weight and maximize strength at the same time. The engineers’ aim must be to encourage more airflow over the component’s surface.

On the other hand, the geometric complexity of 3D printed aerospace components can be excessive. With more complexity, it will take longer to find a suitable supplier and increase machining time. The best solution is to simplify the entire component design at each stage. But complex geometry is usually unavoidable when it comes to aerospace applications, and this is where using a 5-axis machine becomes an ideal solution.

Focus on the right supply manufacturers

Just like sourcing the right materials, finding the most reliable manufacturing partner can be a challenge.

Despite strong competitiveness, not all manufacturers are equal in the aerospace industry. Your goal should be to opt for a digital manufacturing entity capable of meeting the complex requirements of the aerospace industry and your high manufacturing standards.

Transformative manufacturing capability
Gone are the days of conventional, old-fashioned design and manufacturing practices. Today, players like Weyoung CNC are transforming manufacturing capability within the aerospace and defense industry. Unlike iPhones, which sell in their millions, aircraft are produced in small quantities.

In terms of “small batch” manufacturing, CNC machining shines. If you want to be part of the aerospace industry, you’re bound to face one of these challenges. Fortunately, engineers in other industries also face similar problems and apply the same solutions.

Final thoughts
When it comes to advanced aerospace engineering, Weyoung CNC unleashes increased innovation through its supply chain initiatives. Weyoung CNC believes that it’s never too late to optimize the manufacturing process for customized aerospace and defense components.

When it comes to machining large aerospace parts, sales of CNC-machined aerospace components are at an all-time high, and SyncFab continues to lead the way. In the aerospace sector, weyoung cnc has become a leader in CNC machining. Contact us for a free quote today!