{"id":5198,"date":"2022-06-30T22:58:04","date_gmt":"2022-06-30T20:58:04","guid":{"rendered":"https:\/\/www.mecasoft.be\/la-micro-erosion-appliquee-a-laeronautique-et-a-laviation\/"},"modified":"2023-05-09T09:23:42","modified_gmt":"2023-05-09T07:23:42","slug":"micro-erosion-applied-in-aeronautics-and-aviation","status":"publish","type":"post","link":"https:\/\/www.mecasoft.be\/en\/micro-erosion-applied-in-aeronautics-and-aviation\/","title":{"rendered":"Micro-erosion applied to aeronautics and aviation"},"content":{"rendered":"

[vc_row][vc_column][vc_column_text]For the aeronautics<\/strong> and aviation sectors<\/strong>, the machined parts<\/strong> that make up some mechanical components <\/strong>of their engines or actuators require a very high degree of precision<\/strong>. This applies to turbines in particular.<\/p>\n

In order to meet the requirements of the environment in terms of thermal and physical resistance<\/strong>, it is essential that the profiles of these critical aircraft and helicopter parts are designed by micro-erosion machines<\/strong>, capable of unparalleled performance<\/strong>.<\/p>\n

Read our article to learn about the solutions <\/strong>and benefits <\/strong>offered by precision<\/strong> micro-erosion<\/strong> machining<\/strong> for the aeronautics and aviation industries.<\/p>\n

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Precision machining of aircraft and watercraft components<\/h2>\n

For several decades, the aeronautical industry<\/a> has made extensive use of EDM micro-machining<\/strong> to design particularly complex shapes in difficult materials. These are often very strong metals<\/strong> that require a special technique for cutting and drilling<\/strong>, or very particular metals that need to be machined with extreme care.<\/p>\n

In all cases, the profiles are calculated to the nearest micron to achieve the desired performance and reliability, for instance in gerotor or sleeve-piston pump systems. In doing so, they are perfectly in line with the plans designed <\/strong>and tested by specialist engineers<\/strong> and their engineering consultancy agencies. As such, the sub-contracting company responsible for the machining of these metal components needs to master state-of-the-art techniques <\/strong>that leave no room for improvisation. This is where micro-erosion comes in.<\/p>\n

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Example: the importance of micro-holes in aircraft turbines<\/h2>\n

Micro-cooling holes, commonly known as cooling holes<\/em> and made in turbine blades, are a perfect example of the challenges of high precision<\/strong><\/a> micro-erosion<\/strong> machining<\/strong><\/a> techniques<\/strong>. Aircraft engines are subject to extreme temperatures<\/strong> and these limits have consistently been stretched further and further as the aeronautical industry advanced<\/strong>.<\/p>\n

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\"Mirco-trous

Micro-holes for cooling – by O. Cleynen<\/p><\/div>\n

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Cooling is made possible thanks to micro-drilling<\/h3>\n

Current micro-milling<\/strong> technologies allow deep micro-holes to be drilled in the blades<\/strong>, which are the hot parts in the turbines. These are generally a few tenths of a millimetre in diameter (between 300 and 500\u00a0\u00b5m). The holes are crucial because they create internal air circulation, thereby dissipating the heat from the mechanical part<\/strong>.<\/p>\n

The design of the blade is also critical both in terms of shape<\/strong> and surface<\/strong>. Sometimes called a “shape hole”, it acts as a diffuser with its conical profile at the entrance and cylindrical profile inside, which is highly conducive to cooling. It also helps to create a thin layer of air on the surface of the part<\/strong> to improve thermal insulation. The micro-holes are designed to achieve these various goals.<\/p>\n

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Optimum process with micro-erosion<\/h3>\n

The optimum technique for making these holes is micro EDM drilling<\/strong>, which Mecasoft<\/a> fully masters. With this process, we achieve a degree of precision, reproducibility<\/strong> and product quality<\/strong> that would be impossible to achieve with traditional mechanical drilling.<\/p>\n

The performance of micro-milling machines <\/strong>allows for drilling heights of 15\u00a0mm for diameters of 10\u00a0\u00b5m. This is an unparalleled ratio of 150x. The surface finishes obtained are excellent <\/strong>with an Ra <\u00a00.1\u00a0\u00b5m.<\/p>\n

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The benefits of micro-erosion in high-tech sectors<\/h2>\n

In the particularly demanding the civil aviation and, more broadly, aeronautics industries (including defence<\/a>) the accuracy of application and the perfection of machined products<\/strong> are more important than ever. This is made possible thanks to micro-milling and various micromechanical processes<\/a> (cutting, drilling and surfacing).<\/p>\n

Efficiency <\/strong>and productivity <\/strong>are also a constant concern in the aeronautical industry. By using a single electrode diameter, we are helping to automate the manufacturing of these single-blade vanes.<\/p>\n

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Profiling of complex metal parts<\/h3>\n

EDM can be used in the production of aircraft, helicopter and spacecraft engine components<\/strong>, as well as structural metal parts, landing gear parts and tooling components for these sectors. The EDM technology also allows micro-mechanics companies<\/a> to rigorously apply the specifications<\/strong>.<\/p>\n

Mecasoft is capable of producing all types of profiles<\/strong>, even the most complex ones (thanks to our 5-axis micro-milling machine) and from all types of metal, from the most solid to the most delicate.<\/p>\n

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Proficient at ensuring reproducibility<\/h3>\n

Another major advantage of the EDM is its perfect reproducibility<\/strong>. Thanks to remote control via a flawless modern interface<\/strong>, each hole or relief element is exactly the same as all the others. This reproducibility applies not only to a single part but also to all parts in the same series<\/strong>. In doing so, we are able to ensure the consistency and homogeneity<\/strong> of the quality <\/strong>of the finished machined components<\/strong>.<\/p>\n

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In conclusion<\/h2>\n

Mecasoft\u2019s map of customers includes major players in the aeronautics<\/strong>, space <\/strong>and defence<\/strong> industries<\/strong>, such as Airbus, Boeing and Safran, SABCA and SONACA. What is more, our micro-machining company is EN9100:2018-certified. EN9100:2018 is a European standard that allows our customers to rest safe in the knowledge they are getting the quality required by these high-tech sectors (aeronautics<\/a> and aerospace<\/a>). We produce metal components for these companies to ensure aerodynamic, physically and thermally resistant products<\/strong>.<\/p>\n

Interested in benefiting from our high-precision cutting services<\/a> or get in touch with our design engineering department<\/a> to advise you on the development of your product to be machined? Contact us![\/vc_column_text][\/vc_column][\/vc_row][vc_row][vc_column]