In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural elements are being used in the form of monolithic elements, which are replacing the assemblies of parts joined by, for example, riveting. These structures often have a complex, thin-walled geometry with deep pockets. This paper attempts to assess the accuracy of manufacturing thin-walled elements, in the shape of walls with different geometries, made of various aluminum alloys. Machining tests were conducted at different cutting speeds, which allowed comparisons of the geometric accuracy of parts manufactured under conventional and high-speed cutting conditions. Based on the result obtained, it was found that the elements made of EN AW-7075 T651 alloy underwent the greatest deformations during machining in comparison to other two materials (EN AW-6082 T651 and EN AC-43000). An increase in the geometrical accuracy of the manufactured elements was also observed with the increase in the cutting speed for the HSC range. Hence, to minimize the postmachining deformation of thin-walled elements, the use of high-speed cutting is justified.
Keywords: HSC; aluminum alloys; geometrical accuracy; milling; thin-walled elements.