Guide to CNC Machining Aerospace Parts Efficiently
We evidently see the height of human thought in the design and production of flying machines. From rockets, jets to airplanes, they are all tasking to design, leave alone produce. This is why only a few companies ever opt to dive into the aviation set up. Luckily, Creatingway is among the few out there that work on aerospace parts. We achieve this through our team of experts that are adept in rapid prototyping methods. One common method is CNC machining. An aircraft comprises lots of parts that need to be durable and precise. Ensuring that we machine aerospace parts efficiently allows us to produce top-notch parts.
What Problem Do We Face when CNC Machining Aerospace Parts?
Precision machining of aerospace parts comes with many concerns. Firstly, the many parts making up a single aircraft arise from an array of materials. The engine, for instance, is one of the most crucial parts that must work properly. We make it from hardened heat-resistant alloys that are tricky to the machine. They are poor conductors of heat and thus prone to temperature build-up when operating. This is because the heat fails to dissipate away. The precision aerospace parts need is usually stricter than in other industries. Moreover, the geometry of its parts is much more tasking to process.
Other than the direct machining problems, there are a few other indirect issues. One of them is named the production standards. Just like in the medical set up, aerospace parts have to meet strict machining standards. The following guide will depict how we machine aerospace parts efficiently.
How to Machine Thin-Walled Aerospace Parts Efficiently
Weight is a vital factor we consider when CNC machining aerospace parts. Lighter aircraft consume less fuel. Our team of experts thus prefers designing aerospace parts with thin lattices, walls, and webs. Initially, we commence machining on a stamped metal block or solid cast. The resultant waste material of such a process is 95%. However, high material wastage is not the main concern in this case. The actual problem is the high cutting force we have to use. This results in deformation when machining such parts. There is a high risk of breaking the thin walls if we raise the feed and cut depth. This arises from the accompanying vibration. We may also end up producing excess heat that deforms the walls. In such a case, we have to cut away tiny chips at a snail’s feeding rate. This raises the total machining time.
Luckily, our team of experts has come up with a way to lower the machining time. This is enabling us to machine thin-walled aerospace parts more efficiently. The first thing we try to do is to lower the vibration. The thin wall may bend or crack after striking it with a vibrating tool. We achieve this by lowering the feeding rate while increasing the number of cutters. We can opt for multiple cutters in a CNC lathe or several cutting edges in a CNC mill. The best cutting method when milling thin-walled aerospace parts is climb milling. It utilizes a feed that moves in the opposite direction from the normal milling method. Climb milling results in a lower cutting force. It also comes with a better surface finish and lower vibration. The lower vibration arises from the fact that the mill enters the material where its wall is thickest. This allows us to machine the part more efficiently.
How to Reduce Overheating of Aerospace Alloys
Overheating of aerospace parts arises from poor heat conduction. Luckily, our team of experts at Creatingway has come up with a way to counter this issue. The machining strategy is trochoidal milling. It uses the ability of CNC machines to trace complex cutting paths. The trochoidal method utilizes a small mill to follow a path identical to a spring projection on a flat surface. The mill cuts after one curve then return on the second curve, which cuts the metal again. This method lowers the time of contact between the tool and material thus allowing it time to cool.
The technique though has blanker tool runs than normal milling. It luckily negates this by offering increased cutting feeds and speeds. We also offer EDM machining that is much more efficient than precision CNC machining aerospace parts.
Picking the Right Tool for Quick Machining
CNC machines play a big part when it comes to minding the machine tools. This is since it has an array of uses in aluminum machining. One vital way of improving the efficiency of machining is by selecting the right cutting tool. The trick to choosing a tool for any material is trying to counteract its negative properties. In this case, we are dealing with hardened heat-resistant metal alloys. The perfect tool for this case is diamond-cutting tools. They are harder, durable, and cause little vibration. There are also ceramic tools that can work at extremely high temperatures. This helps us improve our efficiency when CNC machining aerospace parts. If you have any inquiries or quotes regarding the machining of aerospace parts, simply contact us.
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