Aeroengine casings have complex geometries and are made from expensive, difficult-to-machine alloys demanded by their increasingly tough operating conditions. Reducing their machining cost while maintaining quality is a critical challenge for many of the AMRC’s partners.

The AMRC casings team has researched casing machining since 2005. From our first studies on metal removal rates and vibrational assessment of current industry methods, we have developed a range of novel strategies, tooling and workholding technologies to optimise casing machining.

We have worked with a leading aeroengine partner to combine many of these techniques into a state-of-the-art machining strategy for specific casings which are now in production.

We develop the technology and application processes to create world-class machining solutions for whole casing component development or single feature optimisation.

We are currently working in areas such as:

  • Metal removal rate improvement.
  • Replicating production challenges by producing multiple components simultaneously.
  • Reduced material input casing technologies.
  • Workholding.
  • Feature-specific tooling.
  • Design tooling for casing geometries.

Key machining resources include:

  • Mori Seiki NVL1350MC vertical lathe.
  • Starrag ZT1000 five-axis machining centre.
  • DMG 160 FD Duo Block

For more information, please contact: 

Sam Fifield, Technical Fellow