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-theart 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 improvements and cycle time reductions
• Working with production engineers to seamlessly transfer research into the manufacturing environment
• Machining vibration & stability optimisation through work-holding, tooling and CAM strategies
• Optimising tool usage and feature-specific tooling
• Driving machining strategies to go ‘green-button’ while maximising productivity and process robustness

Key machining resources include:

• Hermle C52

For more information, please contact: 

Sam Fifield, Technical Fellow
s.fifield@amrc.co.uk