Aircraft Equipment

In the field of aviation, the fusion of precision engineering and reliability are cornerstones of aircraft manufacturing. The precision driving approach of the CNC technology from advanced programming to strict quality control ensures micrometer tolerance. These standards are crucial for the reliability and functionality of the aircraft components. From the engine blades of an aircraft to avionics mounts, for machining metal parts, CNC technology ensures unwavering safety and precision in the aerospace industry.

The Materials Used in Aerospace CNC Fabrication

The materials used in the aerospace industry must possess exceptional qualities and withstand harsh conditions. Some of the desirable qualities in the materials used in aircraft can be fatigue strength, heat resistance, mechanical load resistance, and corrosion resistance.

Repetitive stress cycles on the aircraft components such as wings, and frame can cause fatigue failure, making fatigue strength a crucial property for aircraft materials. The propulsion components of the aircraft are exposed to temperatures that can be as high as 1000C, which requires materials with exceptional thermal stability. During takeoff, landing, and flight the components are subjected to high stress and strain, necessitating materials with a high stress-to-strain ratio. Likewise, due to exposure to moisture and chemicals, the comments require materials with excellent corrosion resistance.

Some of the components used in aircraft are aluminum alloys, titanium alloys, nickel-based alloys, and carbon-reinforced polymers (CRFP). Aluminum alloys, such as 7075-T6 and 2024-T3, offer a good balance of strength, weight efficiency, and corrosion resistance. They are commonly used for structural components, wing ribs, and other parts. Titanium alloys, such as Ti-6Al-4V, provide exceptional strength-to-weight ratios, excellent corrosion resistance, and high fatigue strength. They are ideal for demanding applications such as engine components, landing gear, and critical structural parts.

Nickel-based superalloys, such as Inconel 718, offer superior strength at high temperatures, making them ideal for engine components, turbine blades, and other parts exposed to extreme heat. Composite materials, such as carbon fiber-reinforced polymers (CFRPs), are becoming increasingly popular in aerospace applications due to their high strength, low weight, and excellent fatigue resistance. They are used for various components, including wing skins, fuselage panels, and control surfaces.

How to Machining Aerospace Parts with Precision

CNC machining has revolutionized the manufacturing of aircraft components by offering unparalleled precision, repeatability, and flexibility.

Engine Components

The machining of engine components is carried out mostly by 5-axis machining, which is a type of advanced technique in CNC, that allows for simultaneous machining from multiple angles, significantly enhancing accuracy and geometric complexity. It is ideal for creating parts with complex curves and undercuts, such as turbine blades and impellers. This machining process utilizes multi-axis milling machining with high-speed spindles and advanced cutting tools.

CAD / CAM software is used for tool path optimization for the generation of precise movements and cutting parameters. These paths are optimized using the blade’s complex aerodynamic shape, ensuring smooth material removal and surface finish. The desirable tolerances for the engine parts are in microns and adapting machining techniques are used for achieving such a small range of tolerances. Machining of engine components such as compressor disks involves balancing operations using multi-axis CNC machining. In the machining of combustion chambers, the processes that are involved are milling and turning operations with tools chosen based on the choice of the material i.e., high thermal stability.

Structural Components

The structural components of the aircraft like wing ribs, bulkheads, and fuselage require precise CNC operations. The manufacturing process starts with a face and peripheral milling operations to shape the raw materials into their initial form. To drill holes into the structure for accommodating fasteners, precision drilling and taping are used. Multi-axis machines with high speeds and increased precision are used for extra material removal.

For finishing operations, surface treatments and deburring are used which are a combination of processes such as milling, drilling, contouring, and finishing. These operations are completed with the extreme precision and sophistication required by the aerospace-grade structural components. 

Landing Gear Components

In the machining of the landing gear components such as wheels, brakes, and struts, CNC machining is employed which ensures precision and reliability in aerospace applications. CNC Lathe machines which are equipped with live tooling execute turning operations to shape the complex contours of the landing gear wheels.

For Brake components, CNC milling is the most common process used with the use of high-strength materials. The precision of these machines ensures optimal dissipation and friction characteristics which improves braking efficiency. The struts in the landing gear are manufactured using CNC milling and contouring operations, using aerospace-grade materials like titanium and steel.

Avionics Components

Avionics components occupy the instrument panels, brackets, and mounts in an aircraft. CNC-based operations are designed to ensure precision and durability in these components against vibrations and shocks during the flight. CNC milling, turning, and multi-axis machining are used for fabrication of these components ensuring precise fits for gauges and displays.

These CNC operations are also used for the machining of mounts, providing stability for avionics components along with their fastening mechanisms. The CNC processes ensure that these avionics have exact tolerances and can ensure their resilience and functionality under demanding flight conditions.

Tolerances Requirements in Machining Components

Aircraft components have a tolerance range of micrometers. Tight tolerances ensure that all the parts fit together perfectly and function flawlessly under demanding conditions. These tolerances are attained with the use of Advanced CNC programming, high-precision tools, temperature, and rigorous quality control. Advanced CNC programming enables tool path optimization to minimize wear and tear which leads to reduced dimensional variation.

The cutting tools used in the machining process with exceptional sharpness and stability ensure minimal deviation during the process. Strict temperature control and a robust quality system minimize the thermal expansion of parts and result in stringent tolerances demand in the aerospace industry.

Conclusion

In the aerospace industry, the precision and reliability of the machining components depend on the advancements in CNC technology. During aircraft manufacture, the engine, structure, landing gear, and avionics components go through a series of CNC operations such as CNC milling, turning, facing, drilling, and material removal processes ensuring precision in the parts. Micrometer tolerance levels are achieved using CNC programming, precision tooling, and temperature control of the processes.