Innovation and CNC Aerospace Machining

Since the introduction of Computer Numerical Control (CNC) machine tools, machining has become one of the cornerstones of the modern aerospace manufacturing process. Innovation and CNC Aerospace Machining complement each other. Linked together they drive innovation. The flexibility offered by CNC machines touch all facets of the manufacturing process from prototyping through production. Modern CNC machine tools with state-of-the-art controllers, advanced software and servos, ensure high precision consistently produced components. Being able to machine complex shapes in difficult materials adds to advanced design possibilities, manufacturing flexibility and overall product innovation.

Shrinking the New Design Timeline

CNC machining impacts multiple areas of aerospace manufacturing. One of the most significant areas is shortening the time it takes from design to market. Prior to CNC, new product design and build with its associated development and prototyping could be a long expensive process. It usually involved special fixturing and tooling, all adding time and cost to developing a new product. It became even more cumbersome when multi-axis machining was required. Because of the difficulty involved in fixturing and machining complex shapes, the desired shapes were in some instances simplified or eliminated, shortening product introduction timeline, but lessening product efficiency and limiting innovation.

CNC machines made significant improvements to shortening the time it takes to flow a new design from prototype to production. These machines are designed for flexibility while maintaining or improving precision. Depending on the machine design, most CNC’s can machine 2-3-4-5 axis simultaneously. The multi-axis feature can greatly reduce the need for costly fixturing and work holding. It also can eliminate the need for special form tools.  This gives the designers freedom to design and produce most shapes with efficiency at the forefront. Designers can more quickly assess form, fit, and function, making changes is less costly and time consuming. CNC shrinks the timeline from design to market.

Precision and Repeatability

CNC machines are extremely accurate. Precision and repeatability are their hallmarks. Lathes and milling machines, frequently machine parts to tolerances less than .001” and depending on the application, it is not uncommon to machine components with tolerances below .0005”.  CNC grinders can produce parts in the .0001” range. CNC machines not only achieve these tight tolerances but also repeat these same accuracies from part-to-part, with little or no operator intervention. In aerospace as product requirements become more stringent and shapes more complex, tolerance range continue to shrink. CNC ‘s ability to consistently produce quality components becomes indispensable.

Customization of Complex Geometries

CNC manufacturing is well suited for customization, which is essential for innovation.  In the past using traditional manufacturing methods, they often struggled producing intricate shapes. But using CNC machines, programming and executing complex tool paths which create intricate geometries becomes doable. Additionally, digital design files can be easily modified, allowing for mass customization where each unit can be different—tailored to specific user needs or preferences—without significant fixturing or retooling. Machining complex shapes is now much easier to produce.

Reducing Waste

Optimizing the utilization of raw material and reducing scrap is an additional benefit of this type of machining. The latest generations of CNC subtractive equipment have simulation capabilities which optimize tool paths. The simulation also gives the programmer the ability to maximize cutting conditions prior to cutting the raw material, further enhancing machining conditions, thus reducing waste.

Conclusion

CNC manufacturing is a powerful enabler of product innovation. It gives the originator and manufacturer the ability to design and produce precision complex shapes, in a much shorter timeframe. It allows for flexibility and efficient scalability. It empowers product engineers and builders to push the innovation envelope, shaping and growing the next generation of products.

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