Casing Machining Plan

Industry	Aerospace
Part	Casing
Material	6061-T6
Size	(not specified)
Key Challenges	Closed ring-shaped part, thin walls, low rigidity, high metal removal rate, large deformation
Results	Machining efficiency improved by 30%, measurement efficiency up by 50%, and the machining cycle was greatly shortened.

Technical Challenges

Aerospace shells are mostly closed-loop components. To reduce weight, multiple lightening grooves are distributed inside, and the skin thickness is only 1.2–3mm. To ensure strength, both the wall thickness and rib thickness need to be controlled within a tolerance range (within 0.2mm). The traditional method uses boring machines with side milling heads to machine the lightening grooves, which is inefficient, causes significant deformation, and makes it hard to maintain dimensional accuracy. Additionally, the traditional process involves manually measuring wall thickness, which is time-consuming and results in a long overall processing cycle.

Solution

The BMS5A4025 movable gantry five-axis machining center for beams can achieve efficient machining of aerospace shells. By leveraging the five-axis linkage of the machine and continuously adjusting the tool posture, a larger cutting width can be achieved. Moreover, the machine’s high acceleration and high jerk can reduce corner deceleration time and prevent overcutting at corners, significantly improving machining efficiency. Equipped with an automatic wall thickness measurement system, the machine greatly shortens measurement time and improves measurement accuracy.

Results

Actual tests show that, while ensuring the accuracy of the shape and surface quality, its machining efficiency improved by 30%, measurement efficiency went up by 50%, and the processing cycle was greatly shortened.

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