It’s ironic that the aerospace industry’s increasingly lighter and stronger materials developed to improve aircraft efficiency, durability and sustainability are simultaneously ramping up the challenges for the manufacturers that make its parts. In many respects, aerospace material development is outpacing conventional machine tool technology, forcing parts manufacturers to adapt new technologies and processes.
Titanium alloys and other superalloys such as Kovar (Fe-Ni) and Inconel combine the requisite weight, strength, corrosion resistance and thermal qualities needed in aircraft design. However, the cutting forces necessary to machine these materials generate tremendous heat, degrading part integrity and surface finish. On the other end of the spectrum, materials such as glass, carbon and fiber-metal blended composite laminates are extremely hard, brittle and abrasive, requiring special cutting tools to process them.
Additionally, while new aviation designs incorporate the latest state-of-the-art materials, a significant demand remains to supply the maintenance/replacement part needs of existing airframes and fleets. To meet these and future demands from today’s aerospace OEMs, manufacturers seek technologies that are as adaptable as they are efficient.
As a result, advanced technologies are now taking more prominent roles in aerospace manufacturing. These include:
These processes can efficiently machine hard, difficult materials without the imperfections created by high-heat-affected zones and work hardening, which is often the case with conventional machining processes.
Advances in spark generation have driven EDM’s rise to prominence in aerospace manufacturing. In current EDM technology, the spark is generated at the necessary cutting temperature and then immediately dissipates instead of gradually rising, plateauing and tapering off. The spark melting forces do not penetrate the workpiece deep enough to affect its integrity, and the heat-affected zone is virtually eliminated. EDM machines now generate 300-400 sparks per second directly at the cutting zone, where previously only 80-100 sparks per second were achievable, thus increasing overall production efficiency.
Similar to EDM, laser machining and laser micromachining produce parts with minimal-to-no heat-affected zone for superior surface finish and part integrity. Laser machining provides precision and efficiency when cutting hard and ceramic-coated components, and laser micromachining provides repeatability, precision and accuracy for delicate parts with complex shapes, especially where micron-sized features are involved.
Even with EDM and laser technology replacing traditional milling and turning, the unique—in many cases proprietary and closely guarded—material formulas and complex part shapes require manufacturers to use machine tools dedicated specifically to aerospace production. Machine manufacturers such as GF Machining Solutions have worked for years to adapt their technology for optimal performance in the aerospace sector.
Altogether, modern aerospace design is pushing parts manufacturers hard to find processes suited to the task while making operations efficient and profitable. Using and adapting the latest tools and technology available will be a critical factor in maintaining that balance for future success.
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