Advanced manufacturing techniques and CAM software will expedite the production of complex parts in an aerospace machine shop. As production ramps up, aerospace manufacturers are facing demands to hold the line on costs, improve quality, and speed delivery. This presents an excellent opportunity for aircraft builders and subcontractors to profit from recent manufacturing advances. These include techniques such as high-speed machining and CAM software for machining complex shape.
Complex Surfaces
Engine and fuel-system components typically feature complex surfaces at various angles, containing many holes of different sizes. Positional five-axis machining has proven to be well suited for such parts in an aerospace machine shop. The process aligns and fixes rotary axes before cutting begins. Because it only uses the three linear axes for cutting operations, it’s quite easy to introduce high-speed machining techniques,” explains Peter Dickin, Delcam’s public relations manager.
Drilling Function
Another particularly useful aspect that’s often trivialized, says Dickin, is five-axis drilling. CAM systems can recognize hole features defined in CAD models and quickly orient the drilling head for each hole in a complex part. Fewer fixtures are needed, which saves time and money. And mistakes are eliminated because there’s the potential for error each time the operator repositions a part.
Increased Efficiency
Some components tools to their limits. For instance, machining blisks (bladed disks) from solid blanks is gaining favor over machining individual engine blades and assembling them on disks and shafts. One-piece blisks eliminate tolerance stack-ups and tend to be lighter than conventional rotor assemblies. And since blisk blades cannot shift or move from centrifugal force or blade load, aerodynamics improve, and overall part performance can be more efficient.
Complex Features
Complex, five-axis machining operations seem to get the most attention, but aircraft also include many simpler parts. The move to outsourcing means many of these parts will be made by small, sub-subcontractors that will never own or use complex CAM software. Also, repair-and-replace operations in remote regions need simple parts quickly and consistently.
Advanced Composites
Both Boeing and Airbus plan to increase significantly their use of composite materials. For instance, about 50% of the Dreamliner’s airframe and 25% of the A380 structure will be advanced composites. Recent developments include new methods for generating 2D patterns from 3D CAD models, and improved nesting to ensure the most economical use of materials cut from the sheet.
