CNC Machining a Magnesium Alloy Module Side Bracket for an Aerospace Application
Richconn produced a magnesium alloy module side bracket for an aerospace-related application. The project required precision-machined datum surfaces, H7 precision holes, js6 pin-hole spacing tolerance, and deformation control within 0.05 mm.
Magnesium Alloy Aerospace Bracket with H7 Holes and js6 Pin-Hole Spacing
This project involved the CNC machining of a module side fixing bracket made from magnesium alloy. Although the order quantity was only one piece, the manufacturing requirements were demanding because the part needed accurate datum surfaces, H7 precision holes, js6 tolerance control for related pin-hole spacing, and deformation control within 0.05 mm.
For aerospace-related magnesium alloy components, machining stability is critical. The process must control dimensional accuracy, surface appearance, and deformation at the same time, especially when the part has a large square surface area and multiple precision hole relationships.
Why This Bracket Was Difficult to Machine
The customer required all datum surfaces to be finish-machined, with H7 precision holes and js6 tolerance for the associated pin-hole spacing. At the same time, the part deformation needed to be kept within 0.05 mm.
The component had a square structure and a large overall surface area, making flatness and deformation control difficult during machining.
Main Manufacturing Risks
- H7 precision holes required stable machining accuracy and careful tool control.
- js6 pin-hole spacing tolerance required accurate positional relationship between related holes.
- The large square surface made flatness control more difficult.
- Magnesium alloy machining required careful handling of material stress and surface quality.
- Secondary polishing or grinding could affect the machined surface appearance and dimensional consistency.
The Core Difficulty Was the Combination of Hole Accuracy, Hole Position, and Deformation Control
The machining difficulty came from several factors working together. The precision hole tolerance was high, the distance between related holes required tight control, and the large square surface increased the risk of flatness variation. If stress release, tool runout, finishing sequence, or surface handling were not controlled properly, the final part could fail to meet the required hole accuracy and deformation target.
| Precision Hole Requirement | The part required H7 precision holes, which demanded stable finishing and tight control of machining conditions. |
|---|---|
| Pin-Hole Spacing Requirement | The related pin-hole spacing needed to meet js6 tolerance, making positional accuracy between holes critical. |
| Deformation Requirement | The overall deformation had to be controlled within 0.05 mm after machining. |
| Flatness Risk | The square shape and large surface area made flatness control difficult during and after material removal. |
How We Controlled Stress, Precision Holes, and Surface Appearance
Richconn used a controlled process route to reduce deformation risk and protect the final dimensional relationship between datum surfaces, precision holes, and pin-hole spacing. The key was to manage stress release before final machining and maintain stable finishing conditions.
Rough Machining with Allowance
The outer profile was rough-machined first, leaving a 0.5 mm allowance for later finishing.
Annealing for Stress Relief
After rough machining, the part was annealed to release internal stress and reduce deformation risk before precision finishing.
Tool Runout Controlled to 0.01
During finishing, tool runout was controlled within 0.01 to support stable H7 hole machining and high-speed finishing.
Full Inspection During Machining
Full inspection was performed during the machining process to verify precision holes, hole spacing, and deformation control.
mm deformation control target achieved after process optimization
H7 Precision Holes, js6 Pin-Hole Spacing, and Deformation Control Were Achieved
After process optimization, all required datum surfaces were finish-machined. The H7 precision holes and js6 tolerance for associated pin-hole spacing were fully guaranteed, and the deformation was controlled within 0.05 mm, meeting the customer's requirements.
- Material: magnesium alloy
- Process: CNC machining center
- Precision holes: H7
- Associated pin-hole spacing: js6 tolerance
- Deformation control: within 0.05 mm
- Surface handling: machined tool marks preserved without secondary polishing
What Buyers Should Know About Magnesium Alloy Aerospace Bracket Machining
Magnesium alloy aerospace brackets require more than basic CNC cutting. When a part includes datum surfaces, H7 holes, js6 hole-spacing relationships, and deformation requirements, the machining process must be planned around stress control, finishing allowance, tool stability, and inspection strategy.
For this type of component, surface appearance also matters. Unnecessary polishing or grinding after machining may change the original machined texture and can introduce additional risk to dimensional consistency.
Richconn’s Practical Experience
- Use staged machining to reduce deformation before final finishing.
- Apply stress relief after rough machining when precision stability is critical.
- Control tool runout for precision holes and high-speed finishing.
- Preserve machined surfaces when secondary polishing may affect accuracy or appearance.
- Use full inspection to verify hole accuracy, hole spacing, and deformation during production.
Related CNC Machining Services
Richconn supports custom CNC machining of precision aerospace parts, magnesium alloy components, aluminum brackets, module housings, fixtures, and complex custom metal parts based on customer drawings.
FAQ About Magnesium Alloy Precision CNC Machining
Why is magnesium alloy bracket machining difficult?
Magnesium alloy parts can be sensitive to material stress, surface handling, and deformation. When the component also requires precision holes, accurate hole spacing, and flatness control, the machining process needs careful planning.
What does H7 mean in precision hole machining?
H7 is a common hole tolerance grade used when the hole size must be controlled accurately for assembly or positioning. It requires stable tooling, suitable finishing parameters, and proper inspection.
Why was annealing used after rough machining?
Annealing helps release internal material stress after rough machining. This reduces the risk that the part will deform during or after precision finishing.
Can Richconn machine similar aerospace brackets?
Yes. Richconn can support custom CNC machining of aerospace-related brackets, housings, fixtures, and structural components based on customer drawings, materials, tolerances, surface requirements, and inspection needs.
Need a Magnesium Alloy Part Machined with Tight Hole and Deformation Requirements?
Send us your 2D drawings, 3D files, material requirements, hole tolerance notes, surface requirements, and quantity. Richconn’s engineering team will review manufacturability and provide a practical CNC machining solution.