CNC Machines Have Revolutionized Aerospace

CNC Machines Have Revolutionized Aerospace

The aerospace industry has always been on  the leading edge of technological innovation. Aerospace products are driven by demands for higher precision, greater efficiency, and more reliability. Few  technological changes have impacted aerospace more than the development of Computer Numerical Control (CNC) machine tools. It is not an overstatement to claim CNC machines have revolutionized aerospace. CNC machines are capable of repeatedly generating very complex geometries in various machined sizes and shapes. Because of technological advancements in CNC  hardware and software,  they can predicably produce higher levels of precision components with minimal operator intervention, thus achieving greater  throughput and cost-effective efficiencies.

Definition of a CNC Machine?

At the core of CNC machines is a base platform with a metal (usually cast iron) base. The axes slide movement is achieved using electronic servos that drive ball screws. The ball screws are attached to cross slides  which determine to axis movement, feeds and speeds. The main spindle speeds is also controlled by the CNC controller. Different cutting tools are introduced into the cutting zone via turrets (lathes), milling heads (machine centers).  The axes movement and spindle speeds  (for both lathes and mills) are being directed by the CNC computer controller via a machine program. Most  programs are generated offline through a CAM (computer aided design)software. The generated programs are written in a “machine language”. This machine readable language is usually in a G & M code format, that was developed and expanded during the transition (1950-60’s) from manual to NC to CNC.

The programming language with it’s main and sub routines can generate most geometries necessary to produce complex shapes. The primary  limitations in the machining area are the physical size and tooling with geometries capable of cutting certain materials and achieving tool and chip clearance.  The most common type of CNC machines are lathes, mills (both vertical & horizontal), grinders, and routers.  Many of the later CNC machines are capable of 5 axis simultaneous machining.

Another positive characteristic for using CNC machines is the ability for not only  producing  precision components, but being able to consistently replicate the process. This replication is not dependent on the skill level of the operator. Uniformity of holding tight tolerances becomes very manageable whether in a prototype or high production environment.

Achieving  Accuracy

Aerospace components require ever increasing higher levels of accuracy. Tight tolerance requirements are the norm. CNC machines offer a good solution for achieving these tolerances. There are multiple reasons for the improved accuracies with CNC machines. The current generation machines  are a culmination of years of development and refinement of machine design improvements and advances in servo and controller technology. It is through this combination of machine “mechatronics”, that improved accuracies are achieved. Most of today’s CNC machines can hold and repeat tolerances in the +/- .0005” range, and lower. Not only can these tolerances be achieved, but also repeated.

Manufacturing Efficiency

Like all industries, the manufacturing of Aerospace parts is very competitive. There is an ongoing challenge for producing complex machine shapes, and tighter tolerance components. This is coupled with reducing overall cost.  There are multiple methods implemented that address this multi-pronged challenge but  overriding success is basically achieved through improved efficiencies of the CNC machinery and processes.

An additional challenge to meeting cost reductions are the shortening of lot sizes. The cost of carrying inventory and dealing with constant rev. changes make building up large inventories prohibitive.  CNC machines offer needed flexibility which can lead to shorted setups and turn-around times.

Customization and Flexibility

The aerospace industry often needs a “custom” solution. This requires quick setups and flexible machine software. Using CNC this can many times be achieved without extensive retooling or custom fixturing. Changeover from part-to-part can be quick and efficient.

Summation

CNC machines are at the epi-center  of aerospace machining and manufacturing.  They serve as the core for efficiently producing  high quality, tight tolerance, complex components. Recognizing what it takes to remain relevant in this competitive market, Intrex Aerospace has invested and continues to invest in the latest generations of CNC machines and systems software. If you would like to have more information on our latest machine and software investments, or have a discussion of our capabilities, we would welcome that opportunity. Please click here.