Aerospace components: When precision is key to safety

The aerospace industry is one of the most technologically demanding sectors worldwide. The highest quality standards, maximum process reliability, and the machining of complex, safety-critical components place extreme demands on machines, technologies and expertise. In the aerospace sector in particular, integrated manufacturing solutions are becoming increasingly important to ensure precision, efficiency and reproducibility at the highest level.

WFL says its complete machining solution offers ideal conditions for achieving these desirable outcomes. By combining turning, milling, drilling and grinding in a single set up, complex aerospace components can be manufactured economically and with process reliability. Especially for large, rotationally symmetric or structurally complex components, a WFL MILLTURN machine enables a significant reduction in cycle times and manual intervention.

Typical applications in the aerospace industry include the machining of difficult-to-machine materials such as titanium and nickel-based alloys, high-strength steels or special aluminium alloys. These materials are essential for lightweight construction, temperature resistance and structural strength. However, they place the highest demands on machining strategies, tool technology and machine stability. WFL machines offer the necessary rigidity, performance and precision to reliably machine even the most demanding geometries and tightest tolerances.

Thanks to in-depth aerospace expertise, modern automation concepts and process-integrated measurement technology, WFL’s complete machining solutions form a future-proof foundation for innovative solutions in the aerospace sector, ranging from prototypes and small-batch production to the series production of safety-critical high-end components.

First choice for the aerospace industry

Small batch sizes of complex workpieces made of high-temperature-resistant metals are common in the aerospace sector. Here, maximum precision and process-reliable manufacturing of complex geometries are particularly in demand. The diverse technological challenges of these machining processes usually require specially adapted solutions. With cost-effective manufacturing as the goal, the superiority of complete machining is particularly evident in this industry.

Complete machining of chuck parts 

The complete machining of chuck parts for the aerospace industry is one of WFL’s core competencies. A MILLTURN performs complex machining tasks of this kind with high productivity and precision. For chuck parts with diameters that are often equal to or many times larger than the workpiece length, WFL has developed a competitive advantage over the years. Among the most suitable chuck parts are discs and rings. The latest developments enable the complete machining of chuck parts up to 2000 mm in diameter.

The advantages of machining chuck parts in a MILLTURN:

• Single clamping – complete machining
• Productive four-axis complete machining of disc-shaped chuck parts
• Cutting force compensation via opposing tools for thin-walled workpieces
• Set up of fixtures and workpieces during machining time
• Fast and precise fixture change including the workpiece inside the machine
• Optimal chip flow
• Use of multiple tools simultaneously
• Machining of fit holes with very tight positional tolerances
• Process monitoring
• Manual, semi-automatic or automatic loading
• Significant increase in productivity through maximum coolant pressures and reduced tool wear (for stainless steel materials), coolant supply
• HPC/UHPC (up to 350 bar)
• Automatic change of all tools and measuring probes
• Large magazine capacity
• Maximum productivity and quality
• Automatic concentricity and roundness measurement with scanning probe
• Turn-milling, as an alternative to turning, for interrupted cutting or severe imbalance
• Process design and turnkey solutions from WFL
• Long-term accuracy and durability