CNC Machining a TC4 Titanium Long Connecting Rod for an Aerospace Application
Richconn produced a TC4 titanium alloy long connecting rod for an aerospace-related application. The project required accurate Ø14 bearing holes, 158±0.03 mm hole spacing, and deformation control on a long irregular-shaped titanium component.
TC4 Titanium Aerospace Connecting Rod with Tight Bearing Hole and Hole Spacing Requirements
This case involved the CNC machining of a K1-CN long connecting rod made from TC4 titanium alloy. The part had an irregular long profile, with bearing holes at both ends and strict hole spacing requirements. The key challenge was to control deformation while keeping the Ø14 bearing holes and 158±0.03 mm center distance within tolerance.
Titanium alloy parts such as TC4 are sensitive to machining stress, cutting force, heat, and material removal strategy. For a long irregular component, excessive cutting allowance or an unsuitable machining sequence can easily lead to deformation and hole-spacing deviation.
Technical drawing reference for the TC4 titanium long connecting rod, including the two end bearing holes and center distance requirement.
Why This Titanium Connecting Rod Was Difficult to Machine
The customer needed a long irregular-shaped connecting rod with bearing holes at both ends. The bearing hole requirement was Ø14 with a tight tolerance, and the hole spacing needed to be controlled at 158±0.03 mm.
Because the part was long and made from TC4 titanium alloy, deformation during machining could directly cause the hole spacing to exceed tolerance.
Main Manufacturing Risks
- The irregular long profile increased the risk of deformation during machining.
- TC4 titanium alloy is sensitive to cutting force, heat, and stress release.
- Excessive cutting allowance could cause the part to deform and affect hole spacing.
- The Ø14 bearing holes needed to match the bearing assembly requirement.
- The 158±0.03 mm hole spacing tolerance left little room for machining error.
The Core Difficulty Was Deformation Control on a Long Irregular TC4 Part
The main issue was the relationship between part deformation and hole spacing accuracy. Because the product was long and irregular, and TC4 titanium alloy can deform when machining stress is not properly controlled, a large cutting amount could cause the final 158±0.03 mm hole spacing to go out of tolerance.
| Material Risk | TC4 titanium alloy can deform when cutting force, heat, and internal stress are not properly controlled. |
|---|---|
| Structural Risk | The part had a long irregular profile, making it more sensitive to deformation during material removal. |
| Bearing Hole Requirement | The two end bearing holes required Ø14 machining accuracy for proper bearing fit. |
| Hole Spacing Requirement | The 158±0.03 mm center distance between holes needed to be maintained after machining. |
How We Controlled Deformation and Bearing Hole Accuracy
Richconn used a staged manufacturing route to reduce stress and gradually bring the part to final dimensions. The process combined wire cutting rough preparation, CNC roughing, secondary finishing, shape correction, and final precision hole machining.
Wire Cutting Rough Profile
The outer profile was rough-cut by fast wire EDM with a 1 mm allowance, and the precision holes were pre-cut to Ø13 mm.
CNC Rough Machining
CNC rough machining was performed first, leaving a 0.5 mm allowance for later finishing and deformation control.
Secondary Finishing and Correction
The outer profile was finished to size, followed by shape correction machining to bring flatness to 0.05 mm.
Final Ø14 Hole Machining
The Ø14 bearing holes were precision-machined to final tolerance after deformation control and profile finishing.
mm measured hole spacing achieved against the 158±0.03 mm requirement
Bearing Hole Fit and Hole Spacing Requirements Were Achieved
After process optimization, the Ø14 bearing holes matched the bearing assembly requirement. The 158±0.03 mm hole spacing was measured between 157.99 mm and 158.01 mm, meeting the customer’s tolerance requirement.
- Material: TC4 titanium alloy
- Process: CNC machining center with wire cutting rough preparation
- Bearing holes: Ø14 with tight tolerance requirement
- Hole spacing requirement: 158±0.03 mm
- Measured hole spacing: 157.99–158.01 mm
- Flatness correction target: 0.05 mm
What Buyers Should Know About TC4 Titanium Long Part Machining
Long irregular titanium parts require more than simple CNC machining. When a part includes bearing holes, tight center distance, and deformation-sensitive geometry, the machining process must be planned around staged material removal and dimensional correction.
For TC4 titanium alloy parts, cutting amount, machining sequence, allowance strategy, and final hole machining timing all influence whether the final hole spacing can remain stable.
Richconn’s Practical Experience
- Use wire cutting to prepare irregular titanium profiles with controlled allowance.
- Reduce deformation risk through staged roughing and finishing.
- Leave enough machining allowance before final precision operations.
- Correct flatness before final hole machining when hole spacing is critical.
- Finish bearing holes only after the part geometry is stable.
Related CNC Machining Services
Richconn supports custom CNC machining of titanium alloy parts, aerospace components, bearing-hole parts, brackets, linkages, housings, and complex custom metal parts based on customer drawings.
FAQ About TC4 Titanium Precision CNC Machining
Why is TC4 titanium alloy difficult to machine?
TC4 titanium alloy can be sensitive to heat, cutting force, internal stress, and tool wear. For long or irregular parts, improper machining allowance or cutting sequence can cause deformation and dimensional deviation.
How can hole spacing accuracy be controlled on long titanium parts?
Hole spacing accuracy is usually controlled through staged roughing, proper allowance, deformation correction, stable fixturing, and final precision hole machining after the part shape has become stable.
Why were the holes pre-cut to Ø13 before final Ø14 machining?
Pre-cutting the holes helps remove material gradually and reduce stress before final precision machining. This supports better control of the final bearing hole size and hole spacing.
Can Richconn machine similar titanium aerospace linkages?
Yes. Richconn can support custom CNC machining of titanium alloy aerospace components, linkages, brackets, bearing-hole parts, and other precision parts based on drawings, materials, tolerances, and inspection requirements.
Need a Titanium Part Machined with Tight Hole Spacing Requirements?
Send us your 2D drawings, 3D files, material requirements, bearing hole tolerances, hole spacing requirements, and quantity. Richconn’s engineering team will review manufacturability and provide a practical machining solution.