Internal Machining of Complex Titanium Components

Especially in aerospace, but also in other industries, materials that are difficult to machine – such as titanium, Inconel, or high-strength alloys – are increasingly used. Their machining is typically marked by high heat generation, heavy tool wear, and susceptibility to vibration. Landing gear and turbine components often require extensive and hard-to-reach internal machining, usually without visual inspection during operation. A solution is therefore needed that provides full digital transparency and control, with real-time corrective machine response to changes in cutting conditions or key parameters to meet the highest demands on quality and reliability. Scrap, failures, and machine damage are not an option, and trust in the process and technology is essential. At the same time, tight tolerances are indispensable due to the safety-critical nature of these parts. Economic and sustainability aspects are also crucial, since both components and tooling are highly cost-intensive, while machining a single part can take several days. Minimal disturbances and corrections are the key to reduced lead times.

At the core of the concept are the NILES-SIMMONS TURN-MILL machining center N60 MC, with a machining length of up to 7.5 meters, the sensor-controlled Sandvik Silent Tools™ Plus with next-generation electronics, and the CoroPlus® Connected software. Through a PLC interface developed and programmed in-house by NSH, the tools and the associated monitoring and response software have been fully integrated into the machine control system. This ensures the highest level of safety and transparency throughout the entire machining process. The complete PLC-side integration of the tool sensor system enables real-time monitoring and correction of the process directly during the cut. In contrast to conventional process monitoring methods, such as drive data monitoring, information is now captured live within the tool – at the actual point of operation – and visualized in real time. This significantly increases accuracy, reliability, and safety throughout the entire process, even without direct visual inspection by the operator. 

Instead of merely capturing and visually displaying data, the integration into the control system now allows process-specific limit values to be defined for parameters such as tool load, vibration, deflection, or temperature. When these limits are exceeded, the control system automatically triggers a response. The stop-and-retract function – an emergency withdrawal of the machine – is activated automatically in case of overload or breakage. This enables real-time response to excessive cutting loads, thereby preventing damage or scrap. 

The seamless integration of machine, tool, and software at this level of sophistication is unique worldwide and has been successfully implemented, enabling a process that is up to 30 percent faster and a cutting rate up to 20 percent higher than conventional boring methods or comparable machine solutions currently available on the market.