Titanium Face Milling Integrated with Sinker EDM for Aerospace Components

Background: Precision Surface Requirements in Aerospace

Aerospace components often require perfectly flat and parallel surfaces for proper assembly, sealing, and load-bearing performance. Titanium face milling, combined with sinker EDM for internal features, provides a high-precision solution for these demanding parts.

In this case, aerospace components featured large flat surfaces, deep internal cavities, and precision mounting features. Integration of titanium face milling with sinker EDM ensured tight tolerances, high surface quality, and minimal distortion.

Material Selection and Machinability Challenges

Titanium alloys used in aerospace provide high strength, fatigue resistance, and corrosion protection. Machinability challenges include:

• Low thermal conductivity, leading to localized heat

• Work hardening tendencies

• Difficulty in achieving flat, distortion-free surfaces on large parts

Face milling titanium, combined with controlled milling parameters and post-machining inspection, mitigated these issues.

CNC Titanium Face Milling Process

Titanium face milling operations focused on:

• Creating large, flat reference surfaces

• Achieving precise parallelism and thickness control

• Minimizing thermal and mechanical stresses

High-rigidity CNC machines with precision spindle control were used. Depth-of-cut, feed rate, and spindle speed were optimized for high-speed machining titanium while reducing tool wear.

Integration with Sinker EDM Titanium

After face milling, sinker EDM titanium was used to produce complex internal features such as:

• Deep cavities with precise corner radii

• Complex mounting slots

• Blind pockets requiring minimal taper

Electrode design and EDM parameters were optimized to maintain dimensional accuracy and surface integrity.

Hybrid Machining Workflow

The workflow combined:

1. CNC titanium face milling for external reference surfaces

2. Sinker EDM titanium for internal cavities and precise cutouts

3. Post-EDM finishing via CNC milling to restore flatness and surface finish

This hybrid approach ensured minimal distortion, high precision, and consistent quality across all parts.

Dimensional Tolerance and Surface Quality

Critical tolerances were held within ±0.01 mm. Face-milled surfaces achieved smooth, flat finishes with surface roughness suitable for assembly and sealing requirements.

Inspection included:

• CMM measurement for flatness and feature location

• Gauge checks for functional interfaces

• Surface finish verification for critical faces

Heat Treatment and Stress Management

Due to low heat input during face milling and EDM, heat-affected zones were minimal. Selective stress relief and aging treatments were applied for parts requiring enhanced dimensional stability.

OEM Support and Engineering Collaboration

The project followed an OEM model. Engineering support included:

• Optimizing face milling sequences for precision and flatness

• Designing sinker EDM electrodes for internal features

• Planning post-EDM finishing and inspection

CAD/CAM systems such as SolidWorks, UG, and CATIA were used for programming and simulation. Supported drawing formats included STEP, DWG, DXF, IGS, STL, and PDF. Prototype validation ensured full compliance before production.

Applications in Aerospace

Titanium face milling integrated with sinker EDM is widely used for:

• Aerospace structural components

• Precision fixtures and mounting assemblies

• Components requiring large flat surfaces combined with intricate internal features

This approach ensures both external flatness and internal precision, critical for high-performance aerospace parts.

Conclusion

This case demonstrates how titanium face milling, integrated with sinker EDM, enables production of aerospace components with high precision, flat surfaces, and complex internal features. By carefully controlling machining parameters and combining finishing operations, manufacturers deliver high-quality, reliable machined titanium parts for demanding applications.