Five-axis machine speeds-up aerospace parts manufacture

Early this year, Mubadala Aerospace and Malaysia's National Aerospace & Defence Industries Sdn Bhd (NADI) exchanged a recently signed memorandum of understanding (MoU), under which the parties will explore mutually beneficial opportunities in the areas of joint metallic and composite aerostructure design, manufacturing and assembly, as well as the potential implementation of joint training programs for aerospace engineers and technicians.

Many industries today, especially the high-tech world of aerospace design, are turning to five-axis machining as a means to speed manufacturing ability and increase repeatable accuracy. The ability to machine complex shapes, undercuts and difficult angles in a single setup reduces tooling cost and labour time, resulting in a better cost per part, in addition to maintaining parts conformity throughout the part run.

Five-axis machining centres do not just move in the linear axes X, Y and Z. Instead, these machines also move in two rotary axes, often identified as A and B. The rotary axes tilt the tool with respect to the part. Physically, it can be either the tool that tilts or the part that tilts. Different machines accomplish the rotary motion in different ways. Some machines move the rotary axes only to position the tool or work outside of the cut. This is referred to as 3+2 machining. Moving the tool in this way dramatically increases the machining centre's access to features at different angles or on different faces of the part.
A machine capable of 3+2 machining often can reach all of the machined features of the part in a single setup. True five-axis machining refers to the ability to not just position the tool along the rotary axes, but also to feed the tool through the cut using these axes. Interpolated combinations of A-axis, B-axis and linear axis motions can allow the tool to smoothly follow a contoured surface. This type of machining has long been important in the aerospace industry, where machined parts follow the aerodynamic forms of aircraft.

Five-axis machining capabilities with precision

Makino's new F5-5XR vertical machining centre combines the speed, precision and flexibility required for tight tolerance, five-axis, hard-milling applications. Based upon the F5, the F5-5XR is an affordable five-axis solution for complex aerospace parts.

"The F5-5XR offers the same speed and precision of the F5, but with the added flexibility inherent to five-axis machining centres," said William Howard, Makino's vertical machining product manager. "Using simultaneous five-axis, "2+3 machining" or even simple five-face machining techniques, the F5-5XR helps manufacturers reduce part set-up and handling, cut lead-times, improve quality and lower costs - while providing outstanding precision and fine finishes in very demanding, complex, 3D contoured part applications.

The F5-5XR provides X-, Y- and Z-axis travels of 35.4-inches, 19.7-inches and 17.7-inches, respectively, the 39.4-inch-by-19.7-inch machine work table provides ample room for the 5XR table and workpiece arrangement as well as additional table space for a vice to accommodate other non-five axis work and an optional laser Automatic Tool Length Measurement (ATLM) system.

Aerospace hub

Mubadala Aerospace is driving the development of Abu Dhabi's aerospace industry to establish the Emirate as a global aerospace hub. Furthermore, Mubadala Aerospace and NADI will explore joint defence and commercial maintenance, repair and overhaul (MRO) cross-referral and partnership opportunities. This is part of Mubadala Aerospace's strategy to identify locations for the potential expansion of its MRO network in Asia, connecting it with its existing hubs in the Middle East and Europe. The MoU is focused on the identification and development of opportunities, but does not include any specific commitments for cross-investment by either party at this staADIDAS