Aerospace

Casing Machining Plan

Industry	Aerospace
Component	Dual-arm version
Material	6061-T6
Dimensions	96245861
Main challenges	High metal removal rate, poor rigidity, easy to deform
Results	Deformation and precision met the requirements, closed-angle areas were machined properly, and machining efficiency was significantly improved

Technical Challenges

This part has a double-sided structure with a high metal removal rate and poor rigidity; the edge strips of the part are open, not closed; the wall thickness is thin, only 2.5mm, making it prone to deformation and difficult to maintain machining accuracy; there are multiple closed angles, which are hard to machine.

Solution

Use a machine with good rigidity to reduce vibration during machining, minimize tool wear, and ensure processing quality; the machine can reach an acceleration of 0.4G, allowing fast speed up and down, preventing overcutting at corners due to inertia. Fully leverage the machine's rigidity and high-speed cutting capabilities to quickly remove most of the metal, letting chips carry away heat generated during cutting, reducing part deformation, and improving processing efficiency. Closed angles are machined with specialized corner tools or using 5-axis equipment to adjust the angle.

Results

This effectively solved the key issues of thin-wall open parts being prone to deformation and closed angles being hard to machine, ultimately achieving controllable deformation, qualified accuracy, fully formed closed angles, and improved efficiency with high-quality processing.

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