Thin Walled Machining

Many of the primary components Intrex Aerospace has been producing for many years require thin walled machining capabilities.  We apply our many years of experience, coupled with our state-of-the art CNC machines, to produce high-quality thin-walled parts.

The machining of thin-walled parts can be difficult. It poses problems both in turning and milling. The primary reasons for problems posed during machining thin-walled parts are:

• Poor rigidity
• Part deformation during machining process
• Work holding
• Tooling required

Poor Rigidity

By definition, the workpiece strength is weakened by the thin wall. In most instances, you cannot apply the same tool pressures to the workpieces while machining. A thorough understanding of properly applied tool geometries, along with correct feeds and speeds, are needed.

Part Deformation

Because of inherent part weakness due to the thin wall, parts will have a tendency to deform during the machining process. To be successful, you must have an understanding of what causes the part to deform during the machining process. This deformation has a large impact on being able to control shape and tolerance. Most thin walled parts require a different processing approach from traditional machining.

Work Holding

One of the challenges in machining thin-walled parts is work holding. Due to their design, considerations must be given as to not distort or crush the part. It requires special holding devices, chuck jaws, chuck pressures, etc.

Tooling Required

Experience and understanding of tool geometries is essential to successfully machining thin-walled parts. Machining thin walls poses challenges, so as not to distort the part. Removing metal on thin walls, while avoiding chatter takes knowledge and experience.

Intrex Aerospace has had a long and successful history of producing thin-walled parts in many different sizes and complex shapes. We have made significant investments in CNC equipment that helps facilitate producing thin-walled components.

Our new multi-axis CNC machines require fewer setups. Our five-axis machines can machine nearly every visible surface, excluding the bottom or clamping area. This ability can significantly reduce the need for additional chucking/clamping and, in many cases, eliminates the need for special fixtures. By reducing the number of chucking/clamping, you reduce the possibilities for part distortion.

The design of our newest equipment increases the relational accuracy. Being able to pass the part from one spindle to the other and maintain a single “home” or “zero” reference to the work head helps maintain alignment and eliminates tolerance stack up.

We have produced thin-walled machined parts for many years in the aerospace, defense, and space markets. We have an experienced staff, a robust ERP/MRP system, AS 9100 certification, total system integration and coordination with our customers. We can manage supply needs for low-to-high volume.

We would welcome an opportunity to discuss your thin-wall machining requirements. For more information, contact Intrex Aerospace today.