High-Precision 5-Axis CNC Machined Titanium Alloy Aerospace Structural Components

Customer Region: Germany

Industry: Aerospace

Material: Ti-6Al-4V (Grade 5) Titanium Alloy

Process: 5-Axis Simultaneous CNC Milling & Turning, Shot Peening, Passivation

Order Range: From First Article Inspection to 200 Sets/Month Volume Production

Project Background

Our German customer is a leading aviation equipment manufacturer specializing in next-generation civil aircraft secondary flight control systems. They required a batch of small, high-precision titanium alloy brackets for their new actuator assembly. Aerospace components demand exceptional strength-to-weight ratio, superior fatigue performance, and repeatable micron-level dimensional accuracy. The customer needed a supplier familiar with aerospace machining standards — first completing first article inspection, then gradually scaling up production volume.

Main Challenges

1. Thin-Wall Deformation Risk: The thinnest wall section is only 0.8mm. Complex internal curved geometries are highly susceptible to elastic deformation during machining, with critical mating surface tolerances as tight as ±0.008mm.
2. Titanium Alloy Machining Difficulty: Titanium has low thermal conductivity, leading to high cutting zone temperatures, rapid tool wear, and residual surface stresses that compromise fatigue life.
3. Aerospace-Level Traceability Requirements: Complete material traceability chain, First Article Inspection (FAI) reports, and batch consistency records are mandatory per AS9100 aerospace quality management standards.
4. Surface Integrity Control: Shot peening process parameters must be precisely controlled to ensure a uniform residual compressive stress layer, critical for long-term reliability under cyclic fatigue loads.

Chenrong Technology Solutions

1. DFM Review: Our engineering team optimized thin-wall support structures and tool entry/exit paths without compromising assembly function, reducing deformation risk during machining.
2. 5-Axis Simultaneous Machining: Five-axis machining center completes multi-side machining in a single setup to minimize alignment errors. Cutting parameters are optimized with high-pressure through-tool coolant to effectively control titanium cutting temperatures.
3. Custom Workholding Fixtures: Designed a specialized vacuum + mechanical limiting combination fixture that ensures rigidity for thin-wall parts while avoiding local deformation from hard clamping.
4. Staged Stress Relief: Stress relief annealing after rough machining and aging treatment after semi-finishing gradually release internal stresses, ensuring long-term dimensional stability.
5. End-to-End Quality Control: Every part undergoes full CMM dimensional inspection, Fluorescent Penetrant Inspection (FPI), and ultrasonic testing. Complete material certificates and FAI reports are provided with each batch

Final Results

• First article products passed all tests at the customer's German laboratory on schedule, with 100% dimensional compliance to aerospace drawing specifications.
• Uniform shot peening layer and passivated surface met the customer's stringent fatigue life and corrosion resistance requirements.
• Stable medium-volume production of 200 sets per month achieved with zero deviation across 12 consecutive batches.
• Long-term strategic partnership established; the customer has awarded subsequent three new-generation part development programs to Chenrong.

Customer Testimonial: "The Chenrong engineering team's understanding of aerospace titanium alloy machining is truly professional. They delivered not only high-precision parts but — more importantly — complete process documentation and full quality traceability, which is critical for our aerospace program. We look forward to continuing to deepen our partnership." — Senior Structural Engineer, German Aviation Equipment Manufacturer