Component Overview
A high-stress titanium alloy structural housing for a commercial aerospace subsystem, designed to sustain violent operating vibration. The engineering blueprint specifies Grade 5 titanium (Ti-6Al-4V) per ASTM B265.
Manufacturing Challenge
The structural architecture features a complex unbraced thin-wall geometry with a continuous depth of 45 mm and a targeted nominal wall thickness of 0.60 mm (±0.015 mm).
During initial prototyping by the client’s previous supplier, traditional linear slotting passes induced intense dynamic harmonic resonance (chatter). This produced:
- Rapid tool choking and micro-cracking along grain boundaries
- Wall deformation variance of +0.18 mm (out of tolerance)
- 100% scrap rate
Engineering Solution
Process re-engineering by BOZE:
- Machine platform: High-rigidity 5-axis machining center with hydraulic anti-vibration fixture to stabilize the part base.
- Kinetic toolpath strategy: Transitioned from linear milling to trochoidal toolpaths with constant radial engagement, eliminating harmonic displacement and preventing work hardening.
- Finishing approach: Multi-pass finishing with progressively reduced stock removal (0.15 / 0.10 / 0.05 mm), allowing the wall to stabilize between passes.
Metrology & Verification
Final dimensional verification was executed in a climate-controlled metrology lab using a CMM calibrated to 0.0015 mm accuracy:
| Parameter | Requirement | Measured |
|---|---|---|
| Wall thickness | 0.60 mm ±0.015 mm | 0.605 mm (+0.005 mm) |
| True position | ∅0.02 mm | ∅0.02 mm |
| Surface finish | Ra ≤ 0.4 µm | Ra ≤ 0.4 µm |
| Alpha-case | None | Zero (digital microscopy) |
What This Demonstrates
This example demonstrates our capability to manufacture extreme thin-wall titanium structures — a geometry class that is among the most difficult in titanium machining. If your program requires similar thin-wall or vibration-sensitive geometries, request a process study and our engineers will recommend the fixturing and toolpath strategy for your part.