5-Axis Machining for Complex Aerospace Parts

Aerospace parts tend to be intricate and complex with extremely high tolerance requirements, but a 5-axis CNC machine is capable of achieving tight tolerances even with difficult geometries; compared to machines with fewer axes. Multi-axis machining is a complex process that requires advanced technology and a robust process that can handle the tight tolerances that the aerospace industry demands. At Ultra Precision Machining, we offer accurate and precise parts with every order, and we specialize in government contract work as an ISO 9001: 2015 AS9100D certified machine shop.

To push the envelope of what is possible with 5-axis machining, we utilize the highest grade of available tooling, advanced programming and simulation technology (“digital twin” style simulation), and cutting-edge automation.  Explore the advantages of 5-axis manufacturing and how Ultra Precision Machining can create the detailed parts required for your aerospace applications.

Defining 5-Axis CNC Machining

CNC machining capabilities are classified in terms of how many axes they can work on simultaneously, so 3-axis machining would be able to work on three axes at once. Our 5-axis CNC machining allows us to machine parts along five different axes simultaneously.

The 5 Axes

• X: The cutting tool can move along the X-axis or side to side.
• Y: The Y-axis is used to move the cutting tool forward and backward.
• Z: The cutting tool’s Z-axis allows it to move up and down.
• B: The B-axis allows the workpiece to be tilted side to side about the Y-axis.
• C: The C-axis rotates the workpiece about the Z-axis

5-axis machining allows our professionals to create the complex parts and shapes required for the aerospace industry all while maximizing efficiency. Using the advanced machining technology incorporated in our DMG MORI DMU 50 5-AXIS CNC, we can machine aerospace components with tight tolerances in aluminum (6061, 7050, and aircraft grade 7075), titanium, aerospace grade steels (such as A286, Inconel, Invar, MP35N, etc…) copper, and a variety of other materials.

Advantages of 5-Axis Machining

With 5-axis machining capabilities, Ultra Precision Machining can offer the aerospace industry several notable advantages for both full production runs and prototyping. With this technology, we can efficiently produce reliable parts that maintain tight tolerances, from specialty materials designed to perform at intense pressures, elevated temperatures, and in high-performance applications.  These advantages include:

• Cost savings for production run through Setup Reduction and 5-axis Specific Tooling
• Advanced Programming and Simulation, allowing us to increase accuracy and first-piece yield
• Extremely high capability for Automation
• High variation of material compatibility

Setup Reduction – Decreased Operational Costs

Our 5-axis machine allows us to hold the part in a single workholding solution throughout a large majority of the machining process. This allows the overall efficiency of the process to be vastly improved, which leads to shorter turnaround times and cost savings on production runs. 5-axis machining also significantly reduces the lead time for prototyping projects. The ease of setup helps reduce scrap production and improves the overall quality of the components.  Additionally, by using 5-axis specific tooling, we can increase tool life and hold even tighter cutting tolerances than what is possible on traditional 3-axis machines.  For production runs, this can equate to even more cost savings for our customers as well as less tool management for us – an overall process improvement.

Advanced Programming and Simulation

5-axis machining requires the use of some of the most complex software in the industry to be able to perform at the highest level of manufacturing. By utilizing the modern programming (CAD and CAM) software, as well as industry-leading simulation software, we can accurately predict how the 5-axis CNC will behave and machine components well before the part goes into production. The simulation software that we use (Vericut) accurately simulates the cutting process of the material as well as the entire 5-axis machine and all of its interior components.

This allows us to error-correct our programs and look for efficient cutting processes in advance. The software will fully simulate every tool and machine move, flag any potential issues, and identify areas of improvement for the programmer to review. This also gives us the incredible advantage of increasing first-part yields and avoiding collisions during the extremely complex 5-axis simultaneous movements.

Full Automation of the Machining Process

Automation has become increasingly important to the modern machine shop. It allows for unattended operation and process repeatability. When coupled with a 5-axis machine, automation can be a force multiplier. Traditional 3-axis machines can use automation, but a 3-axis serving robot can only load raw material or parts to run the single operation that is currently set up in the machine. With 5-axis integration, we can have an automated support machine load raw material into the machine and, in most cases, completely machine the entire part.

The pallet loader can then remove that pallet (which includes the work holding setup and the part itself) and replace it with another one. The benefit of this setup is that the next pallet that is loaded can be the same part or a completely different part regardless of size, material, or complexity. This process can be used on 10 different pallets, which allows us to increase our output from this single machine by an order of magnitude. Coupling this with our DMU 50 (3rd Generation) 5-axis milling machine’s state-of-the-art tool management (with laser inspection), workpiece inspection probe tool, and increased tool storage capacity (130 tools), we can offer revolutionary levels of automation.

Materials Used in the Aerospace Industry

Our machine shop has experience working with a wide range of materials for the aerospace industry, and our 5-axis machine capabilities make working with these materials much easier and faster. Throughout the industry, it’s common to use materials like lightweight aluminum, such as 6000 series for structural components, as well as 7000 series aluminum for flight hardware in space and aerospace applications. Aerospace components often operate in highly demanding environments and must be high-temperature resistant. These high-temperature metals such as titanium, Inconel, Invar, A286, and MP35N present significant challenges to machining, but with the high rigidity and accuracy of our 5-axis machines, we can tackle these materials with a much greater degree of efficiency.

High-temp metals are frequently seen in engine components and are integral to the successful operation of aerospace systems. Our machine shop can additionally work with machinable plastics, which are used throughout the aerospace industry for applications such as spline adapters in helicopters.

Our Commitment to Quality Precision

Ultra Precision Machining has extensive experience working in the aerospace industry, and this is largely due to our quality department. Given the significant demands of aerospace parts in terms of dimensional accuracy and precision, our quality department utilizes a system that begins with open communication with our customers. We want to understand exactly what customers need and expect, so we know how to move forward and exceed those expectations.

Our first article inspections are carried out with either 100% inspection or statistical sampling to guarantee quality. This sampling is done using AQL sampling methods to keep our efforts consistent and accurate. Additionally, we keep separate quality documents for each customer that are updated as needed to ensure we are delivering the quality results that are expected of us. For transparency, we keep all of our relevant material and finish certifications for up to 10 years.

AS9100 Certified 5-Axis Machining

Ultra Precision Machining is AS9100 certified, which allows us to offer machining services for the aerospace industry that are up to a globally accepted standard. With the aerospace industry’s unique quality management requirements, our commitment to meeting this standard is at the core of all our operations.

ITAR Registered

As an ITAR-registered machine shop, we offer services for the aerospace industry including aspects that cross over with the defense industry. The government requires all entities that engage in the manufacturing of defense components, such as what many aerospace projects call for, to be ITAR-registered. Ultra Precision Machining is registered with the State Department’s Directorate of Defense Trade Controls with the knowledge necessary to work for the defense sector of the aerospace industry.

Why Choose Ultra Precision Machining

Ultra Precision Machining is a highly experienced machine shop, with 5-axis machining capabilities for complex aerospace parts, as well as 3-axis CNC milling and CNC lathe turning capabilities for a multitude of applications. Our ITAR-registered ISO 9001: 2015 AS9100D certified quality control makes our services ideal for both large production orders and parts for prototype builds with precision and accuracy. With over 25 years in precision manufacturing and an experienced staff of programmers and machinists, we can offer the accurate results that the aerospace industry requires. Our team has made thousands of unique parts for a multitude of companies over the years including defense and government contractors like L3HARRIS, Lockheed Martin, Leonardo DRS, and Collins Aerospace. Coupled with our competitive pricing and commitment to exceptional quality, our customers can expect immediate benefits in using us on their next project. Request a quote today for your aerospace 5-axis machining project.

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