Custom Titanium Machining for Aerospace Fasteners with CNC Milling and Turning

Background: Aerospace Fastener Requirements

Aerospace fasteners must meet stringent standards for strength, precision, and corrosion resistance. Titanium fasteners are favored for their high strength-to-weight ratio and resistance to extreme environments.

In this case, the customer required custom titanium fasteners with threads, hex heads, and precision shank diameters. CNC titanium milling and turning were combined to produce high-quality, repeatable parts.

Material Selection and Machinability Considerations

Titanium alloys were chosen for their corrosion resistance, strength, and biocompatibility (for aerospace interior fasteners). Machinability challenges include:

• Low thermal conductivity and potential heat buildup

• Work hardening during threading or turning

• Tool wear during precision milling

Custom titanium machining required careful tool selection and process parameter optimization to achieve consistent quality.

CNC Titanium Turning Process

Titanium turning was used for:

• Shank diameters with tight tolerances

• Thread cutting (internal and external)

• Chamfers and radii for assembly ease

High-speed CNC turning ensured accurate threads and surface finish while minimizing tool wear and heat generation.

CNC Titanium Milling for Functional Features

Milling operations included:

• Hexagonal head milling for torque engagement

• Pocket milling for countersinks and recesses

• Slot and flat milling for specialized assembly interfaces

High-speed machining titanium parameters were carefully controlled to maintain dimensional accuracy and surface integrity.

Dimensional Accuracy and Surface Finish

All fasteners were held within ±0.01 mm tolerance for critical features. Surface finish met aerospace standards for functional and torque-critical surfaces. CMM inspections verified thread profiles, flatness, and dimensional compliance.

Heat Management and Stress Control

CNC titanium turning and milling were optimized to minimize heat generation. No post-machining heat treatment was required for most fasteners, although selective stress relief was applied for large batch production of critical fasteners.

OEM Support and Engineering Collaboration

This project was executed under an OEM model. Engineering collaboration focused on:

• Optimizing turning and milling sequences for complex fastener geometries

• Ensuring thread accuracy and torque integrity

• Prototype validation before mass production

CAD/CAM tools such as SolidWorks, UG, and CATIA were used. Supported drawing formats included STEP, DWG, DXF, IGS, STL, and PDF.

Applications in Aerospace

Custom titanium machining for CNC milled and turned fasteners is widely used for:

• Aircraft structural assemblies

• Engine components and brackets

• Aerospace interior and exterior fixtures requiring high precision

This combination ensures strength, dimensional accuracy, and reliability in critical aerospace applications.

Conclusion

This case demonstrates how custom titanium machining, combining CNC milling and turning, produces high-quality aerospace fasteners. Optimized machining parameters, precision tooling, and inspection protocols ensure reliable, high-strength titanium parts suitable for demanding aerospace requirements.