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Aerospace Case Study 01 / 15

Aircraft Structural Part Machining Case Study

Unlike ordinary industrial parts, aerospace structural components must satisfy:

aircraft structural part machining case studyaerospace cnc machining5 axis aerospace machining
Aircraft Structural Part Machining Case Study

Case Overview

Core project data for this machining case.

Industry Aerospace
Product Aircraft Structural Parts
Material 7075-T6 / 2024-T351 / 7050 / Ti-6Al-4V
Process Forging + Heat Treatment + 5-Axis CNC Machining
Machine Model HYR VMC850 / VMC1165 / 5-Axis Machining Center
Tolerance +/-0.005 ~ +/-0.01 mm
Surface Finish Ra0.4 ~ Ra0.8
Application Commercial Aircraft / Military Aircraft / UAV / Spacecraft

Customer Background

Production context behind the case.

This project comes from a Aerospace manufacturing requirement for Commercial Aircraft / Military Aircraft / UAV / Spacecraft. The buyer needed stable machining quality, repeatable inspection results and a machine configuration suitable for real production rather than a one-time sample.

Machine Selection

Why this machine configuration was selected.

HYR-CNC selected the machine plan around part size, material, tolerance, surface finish, tool capacity and expected production volume. The recommended setup focuses on rigidity, spindle stability, fixture access, tool change efficiency and inspection control.

Problem

Machining problem to solve

Forging creates: Material strength Grain flow Basic geometry But forging cannot achieve: Thin wall structures

Solution

HYR-CNC machining plan

The customer is an aerospace supplier producing: Wing ribs Bulkheads Fuselage frames Engine mounts Cabin structures

Machine Used

Recommended machine configuration

Machine: HYR CNC machining center selected according to aerospace material, part size and tolerance
Process: Rough machining, semi-finishing, 5-axis finishing and inspection based on the document content
Accuracy Control: Rigid fixturing, thermal stability, deformation control and CMM inspection
Cost Method: Published with existing website assets first to keep implementation cost low

Process

Timeline from raw material to inspection.

01 Material preparation
02 Rough machining
03 Semi-finishing
04 5-axis finishing
05 Inspection

Full Case Article

Machining background, difficulty and solution logic.

Quick Facts

Item

Details

Industry Aerospace Product Aircraft Structural Parts Materials 7075-T6 / 2024-T351 / 7050 / Ti-6Al-4V Manufacturing Process Forging + Heat Treatment + 5-Axis CNC Machining Machine HYR VMC850 / VMC1165 / 5-Axis Machining Center Tolerance +/-0.005 ~ +/-0.01 mm Surface Finish Ra0.4 ~ Ra0.8 Application Commercial Aircraft / Military Aircraft / UAV / Spacecraft

Introduction

Aircraft structural parts are the skeleton of an aircraft.

Every aircraft contains thousands of structural components.

Aircraft structural part machining is one of the most demanding manufacturing processes in the world.

They support: Wings Fuselage Tail sections Landing gear Engine mounts Cabin frames Cargo structures Control surfaces A modern commercial aircraft may include: 50,000+ Structural Parts 100,000+ Machined Features Millions of Precision Dimensions Unlike ordinary industrial parts, aerospace structural components must satisfy: Ultra-Light Weight High Strength Excellent Fatigue Resistance Extreme Reliability The machining quality of these parts directly affects: Flight safety Structural rigidity Fuel efficiency Aircraft weight Fatigue life Therefore:

Customer Background

HYR CNC provided a dedicated aerospace machining solution.

The customer is an aerospace supplier producing: Wing ribs Bulkheads Fuselage frames Engine mounts Cabin structures UAV structural components Annual production: 80,000+ Aerospace Structural Parts Materials include: 7075-T6 2024-T351 7050 Aluminum Ti-6Al-4V Titanium Alloys Challenges: Thin wall deformation High material removal rates Titanium machining difficulties Long cycle times Strict dimensional tolerances

Industry Background

Modern aerospace manufacturing is evolving rapidly.

Lightweight Design

This significantly increases machining difficulty.

Aircraft manufacturers continuously pursue: Lower Weight Lower Fuel Consumption Longer Flight Range Therefore: Structural parts are designed: Thinner Larger More integrated

Integral Machining

Traditional design: Many Small Parts Bolting Assembly Modern design: Single Large Monolithic Part 5 Axis Machining Direct Assembly Benefits: Reduced weight Better rigidity Fewer fasteners Improved fatigue resistance

Composite Aircraft Structures

Metal structural parts still play a critical role.

New aircraft increasingly adopt: Carbon fiber Aluminum-lithium alloys Titanium alloys High-strength aluminum

Common Aircraft Structural Parts

Typical aerospace structural components include:

Wing Rib

Support wing aerodynamic shape.

Function: Characteristics: Large Size Thin Wall Complex Geometry Materials: 7050 Aluminum 7075 Aluminum

Bulkhead

Separate aircraft sections.

Function: Characteristics: Circular structures Thin ribs High rigidity Materials: Aluminum alloys Titanium alloys

Fuselage Frame

Maintain fuselage strength.

Function: Characteristics: Large Diameter Thin Wall High Accuracy

Engine Mount

Connect engine and fuselage.

Function: Requirements: High Strength Fatigue Resistance Impact Resistance Common material: Ti-6Al-4V

UAV Structural Components

Applications: Military UAVs Commercial drones Surveillance aircraft Requirements: Lightweight High stiffness Excellent surface quality

Material Selection

Aerospace materials are among the most advanced engineering materials.

7075-T6 Aluminum

Known as: Aircraft Grade Aluminum Advantages: High strength Good machinability Lightweight Applications: Wing ribs Structural brackets Frames

2024-T351 Aluminum

Advantages: Excellent fatigue resistance High toughness Applications: Fuselage structures Bulkheads Frames

7050 Aluminum

Advantages: Superior corrosion resistance Excellent fracture toughness Applications: Wing structures High-load components

Ti-6Al-4V Titanium

Advantages: High Strength Low Density Excellent Corrosion Resistance Applications: Engine mounts Landing gear Spacecraft structures Disadvantages: Extremely Difficult To Machine

Why CNC Machining Is Necessary

Precision CNC machining is indispensable.

Forging creates: Material strength Grain flow Basic geometry But forging cannot achieve: Thin wall structures Precision holes Complex pockets Weight reduction cavities Therefore:

Material Removal Rate

Aerospace structural parts often start from: 100 kg Forging 10 kg Finished Part Material removal: 90% Extremely high removal rates require: High spindle power Stable machine structures Excellent chip evacuation

Thin Wall Machining

Typical wall thickness: 0.8 mm 3 mm Challenges: Deformation Chatter Vibration

Large Integrated Parts

Some structural parts exceed: 1500 mm 3000 mm Requirements: Stable thermal control High machine rigidity Accurate positioning

Machining Challenges

Aircraft structural parts are notoriously difficult to machine.

Challenge 1

Thin Wall Deformation Reasons: Low stiffness High cutting forces Residual stresses Possible defects: Distortion Vibration marks Dimensional instability

Challenge 2

High Material Removal Typical removal rate: 80% 95% Challenges: Long machining times Heat accumulation Tool wear

Challenge 3

It is one of the most difficult aerospace materials to machine.

Titanium Machining Titanium suffers from: Poor Thermal Conductivity High Cutting Temperature Tool Wear Built-Up Edge

HYR CNC Solution

HYR recommends:

HYR VMC850

Suitable for: Small structural parts Aluminum aerospace components Travel: 800×500×500 mm Advantages: High-speed machining Excellent aluminum cutting Superior surface quality

HYR VMC1165

Suitable for: Large structural parts Titanium components Travel: 1100×650×650 mm Advantages: High rigidity Stable cutting Heavy-duty machining

Future 5-Axis Machining Center

Suitable for: Wing Ribs Bulkheads Blisks Complex Aerospace Structures Advantages: Multi-angle machining Fewer setups Better accuracy

Step 1

Forging Produce: High strength blanks Optimized grain flow

Step 2

Heat Treatment Improve: Strength Fatigue resistance

Step 3

Rough Machining Remove: 70% 85% Material Machine: Pockets Cavities Profiles

Step 4

Prepare for finishing.

Semi Finishing Reduce: Residual stress Thermal distortion

Step 5

Finish Machining Requirements: Tolerance +/-0.005 mm Ra0.4 Machine: Thin walls Holes Interfaces

Step 6

Improve assembly quality.

Deburring Remove: Burrs Sharp edges

Step 7

Guaranteeing aerospace standards.

CMM Inspection Inspect: Dimensions Hole positions Profiles

Cutting Parameters

Item

Value Spindle Speed 10000 rpm Feed Rate 2500 mm/min Tool Material Carbide Coolant High Pressure Depth of Cut 0.5 mm Surface Finish Ra0.4

Quality Inspection

Every aerospace structural part undergoes strict inspection.

Dimensional Inspection

Requirement: +/-0.005 mm Inspect: Linear dimensions Hole positions Geometric tolerances

Surface Inspection

Requirement: Ra0.4 Inspect: Roughness Surface waviness Tool marks

CMM Inspection

Requirement: 100% Inspection Verify: Profiles Hole positions Flatness

Material Certification

Ensuring full traceability.

Verify: Chemical composition Heat treatment records Mechanical properties

Results

Item

After adopting HYR CNC machining solutions: Before After Surface Finish Ra0.8 Ra0.4 Dimensional Accuracy +/-0.02 mm +/-0.005 mm Cycle Time 180 min 125 min Scrap Rate 2.0% 0.2% Material Utilization 82% 90% The customer achieved: Better dimensional stability Improved fatigue performance Higher production efficiency Lower manufacturing costs Greater product reliability

HYR VMC850

Recommended for: Aluminum Aerospace Parts UAV Components Structural Brackets

HYR VMC1060

Suitable for: Medium Structural Parts Titanium Components

HYR VMC1165

Ideal for: Large Structural Parts Aerospace Frames Engine Components

Related Articles

What Is 5 Axis CNC Machining?

Wing Rib Machining Case Study Bulkhead Machining Case Study Landing Gear Component Machining Case Study Titanium Machining Case Study Thin Wall Aerospace Part Machining

What are aircraft structural parts?

Aircraft structural parts are load-bearing components such as wing ribs, bulkheads, frames and engine mounts that form the aircraft's structural system.

Which materials are commonly used?

7075-T6, 2024-T351, 7050 aluminum and Ti-6Al-4V titanium are widely used.

Why is aerospace machining difficult?

Because aerospace parts require: Thin wall structures Tight tolerances High material removal Difficult-to-machine materials

Why is titanium difficult to machine?

Titanium has poor thermal conductivity and generates high cutting temperatures, leading to rapid tool wear.

What tolerance is required?

Most aerospace structural parts require tolerances between: +/-0.005 mm +/-0.01 mm

Which CNC machine is recommended?

HYR VMC850, VMC1060 and VMC1165 are excellent solutions for aerospace structural machining.

Conclusion

Aircraft structural parts are among the most demanding components in aerospace manufacturing.

From wing ribs and bulkheads to engine mounts and titanium structures, every feature requires precision CNC machining.

With excellent rigidity, stable dimensional accuracy and advanced aerospace machining capabilities, HYR CNC machining centers provide reliable and efficient solutions for aircraft structural part manufacturing.

HYR CNC continues to support global aerospace manufacturers with advanced machining technology and customized production solutions.

Result

Before and after machining improvement.

ItemBeforeAfter
Result 1Before optimizationAfter adopting HYR CNC machining solutions:
Result 2Before optimizationSurface Finish
Result 3Before optimizationRa0.8

FAQ

Common buyer questions for this case.

What is this aerospace article about?

This page covers aircraft structural parts requirements, machining difficulty, process planning and machine selection.

Which machines are recommended?

HYR VMC, HMC and 5-axis machining centers are selected according to material, size, tolerance and contour complexity.

Can HYR-CNC support similar aerospace parts?

Yes. Send drawings, material, tolerance and production volume for a suitable machining proposal.

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Use the download center to review machine catalogs, brochure files and supporting documents before requesting a quotation.

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Similar Case Studies

More Aerospace machining proof.

Wing Rib Machining Case Study

A wing rib is one of the most important structural components inside an aircraft wing.

Bulkhead Machining Case Study

A bulkhead is one of the primary load-bearing structures inside an aircraft.

Fuselage Frame Machining Case Study

The fuselage frame is one of the primary structural components of an aircraft.

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