Introduction to Aerospace Manufacturing Processes

The aerospace manufacturing industry continues to grow and advance. In recent decades, the industry has seen the development of several important processes. These processes cover everything from part forming to part and material finishing. R&S Machining, Inc. has extensive knowledge and experience in all areas related to aerospace and defense component manufacturing.

While there are many key aerospace manufacturing processes, here are 5 processes that everyone in the industry should be familiar with:

Aerospace Manufacturing Processes

1) Milling

Milling is one of the most common machining processes in the aerospace industry; it is most often used to make cuts within a workpiece. These cuts range from simple lines and shapes to more complex designs and detailed levels. The most common milling processes include:

1. Vertical Milling
2. Horizontal Milling
3. Side Milling
4. Profile Milling
5. Face Milling

The type of milling process used depends on the material and the needs of the finished part.

2) Swiss Turning

Swiss machine tools have become increasingly popular over the years due to their ability to turn smaller, more complex workpieces. Swiss turning can also produce large quantities of parts quickly and is generally less expensive than other turning methods. The bar stock of a Swiss lathe rotates and slides through a guide bushing. This provides a strong support point to machine workpieces of various lengths. This also provides the support needed to create smaller and more intricate details within the workpiece.

3) Hard Turning

Hard turning is a finishing process that offers several advantages over other methods. Since the basic principles of hard turning are similar to other “soft turning” methods, machinists are often able to quickly learn to apply their skills to hard turning. Other finishing processes, such as grinding, often require specialized training. When you need to finish complex workpieces or internal and external geometries, hard turning is the solution you need.

4) Grinding

During the grinding process, the workpiece is smoothed and irregularities are removed. This makes the workpiece consistent with other workpieces produced. The advantage of grinding is that it can be used on most types of workpieces, regardless of shape or size. Many customers in the aerospace industry require manufacturers to grind to complete their products.

Like other finishing and machining methods, there are many different grinding processes. The most common grinding processes include:

1. Cylindrical Grinding
2. Profile Grinding
3. Surface Grinding
4. Centerless Grinding

5) 5-Axis CNC Machining

The key to 5-axis CNC machining lies in technological advancements that have allowed more sophisticated machines to machine parts in 5 and 6 axes. 5- and 6-axis CNC machining allows the workpiece and tool head to move, rotate, and tilt within the machine to machine hard-to-reach areas and shape complex geometries. In the aerospace industry, where every micron counts and parts are put into systems that demand perfection, 5- and 6-axis machining can achieve the precise quality you need.

These are just a few of the many processes used in the aerospace manufacturing industry. Each process has its purpose and place in the overall production process. Xavier is proud to offer several of these technologies and processes in our machine shop, as well as many more not listed here. To learn more about the products and services we offer, contact us today!