Machining of Complex Integral Airframe Structures

Currently the construction of complex aircraft structures such as the skeleton within a wing is extremely time consuming and expensive. Traditionally these structures are assemblies of sheet metal parts, machined parts and composite parts, which are bonded and riveted together. Replacing an assembly of this type with a single machined part has the advantages of reducing the total number of build hours, decreasing weight, and increasing strength, but the machining techniques used for this are very expensive. There have been a number of advances in machining techniques and equipment, which may allow an entire wing skeleton type of structure to be affordably machined as one piece with a minimal number of set-ups using much smaller machines. The combination of Plunge rough cutting, Sonically tuned milling equipment, Heat shrink coupling of cutting tools, Cutting tools designed with frequency in mind, Relieved cutting tools, and the use of High-speed fluid driven or gear driven right angle heads will allow smaller machines to build affordable complex integral aircraft structures from aluminum or titanium, like those found in aircraft such as the F-35A.