Titanium Plasma Cutting and High-Speed Machining for Aerospace Brackets

Background: Precision Brackets for Aerospace Applications

Aerospace brackets often combine thin walls, cutouts, and high-strength profiles. Titanium plasma cutting allows rapid separation of raw titanium plates, while high-speed machining ensures precise final dimensions and surface quality.

In this project, titanium brackets were required for aerospace fixtures and assemblies. The combination of titanium plasma cutters and high-speed CNC machining provided fast, accurate production with minimal distortion.

Material Selection and Machinability Considerations

Titanium alloys were chosen for their corrosion resistance, fatigue strength, and weight savings. Machinability challenges include:

• Low thermal conductivity, causing heat buildup

• Work hardening tendencies

• Difficult cutting edges for sharp corners

Titanium plasma cutters allowed initial rapid cutting, followed by high-speed machining titanium to achieve precise features and surface finish.

Titanium Plasma Cutting Process

The plasma cutting process included:

• Securing titanium sheets with precision fixtures

• Adjusting plasma cutting parameters for material thickness

• Cutting near-net-shape blanks for CNC finishing

Plasma cutting provided rapid material removal and accurate preliminary shapes. The heat-affected zone was minimized through optimized cutting speed and plasma settings.

High-Speed Machining Titanium for Precision Features

After plasma cutting, high-speed CNC machining operations produced:

• Titanium milling for slots, pockets, and ribs

• Titanium turning for cylindrical features

• Drilling and finishing operations for assembly interfaces

High-speed machining titanium reduced cycle times while maintaining dimensional accuracy and surface quality.

Dimensional Accuracy and Surface Quality

Critical tolerances were maintained within ±0.01 mm. Surface finishes met aerospace requirements for assembly, load-bearing, and sealing interfaces.

CMM inspections and gauge checks ensured dimensional compliance. Edges and cutouts from plasma cutting were refined during CNC machining.

Heat Management and Stress Control

Titanium plasma cutting introduced minimal heat due to optimized parameters. High-speed machining titanium minimized tool-induced heat buildup, preserving the material’s mechanical properties.

Selective stress relief was applied for parts with critical flatness or alignment requirements.

OEM Support and Engineering Collaboration

This project followed an OEM manufacturing model. Engineering teams collaborated to:

• Optimize plasma cutting paths and cutting parameters

• Plan high-speed machining operations for precision features

• Validate prototypes for fit and function

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

Titanium plasma cutting combined with high-speed machining is widely used for:

• Aerospace structural brackets

• Lightweight mounting assemblies

• Complex titanium components requiring rapid material removal and precision finishing

This integration allows manufacturers to deliver high-quality machined titanium parts efficiently.

Conclusion

This case demonstrates how titanium plasma cutting, combined with high-speed CNC machining, enables production of precise aerospace brackets. By controlling cutting parameters, machining sequences, and finishing operations, manufacturers achieve high-quality, distortion-free titanium parts with tight tolerances and excellent surface finishes.