I'm not an aerospace engineer but I have done allot of research in the area because I'm also considering it as a prospective career; Since no one else has replied thus far, I feel like I can help you out.

1) AE's (Aerospace Engineers) design both aircraft and spacecraft . If you do decide to become an AE then you will probably find yourself working in the aeronautical industry as jobs in astronautical projects are scarce. You can get jobs at places like NASA and ESA but they tend to be highly competitive.

2) You really need to do this reasearch yourself. You have to consider what universities have decent courses and which ones aren't worth bothering with. You need to work out what qualifications you need in order to get on the course and you also have to decide whether you want to do a course in specifically AE'ing or related courses like Electrical and mechanical engineering which would also allow you to work in the Aerospace industry as an AE.

I would give that last point some deep thought because AE is a very specialised field and jobs in the field tend to have a habit of dissipating whenever companies go bust or when large projects end. (A good example is the shuttle project which apparently employed many AE's in Florida. But when the Shuttle project ended then all those jobs dissapeared). MechEng and ElecEng tend to have far more job opportunities which you will be able to take if you can't find a job in the aerospace industry.

3) Besides CAD applications, I don't really know. This article gives you an idea of the day to day work:
http://www.makeit.org.uk/a-day-in-the-life/a-day-in-the-life-of-a-aerospace-engineer/index.html
Bear in mind that the kind of work you end up doing can be very varied.

4) I'm not an AE so I can't answer this.

5) Or this.

6) After all my research I would say that it's very improtant you get the grades you need to do a course at university. In the UK those would normally be Maths, Physics and another science A level (I think their equivelant to APs or whatever you do from 16-18 in the US or wherever) .
Also, you need to make sure that you are strongly motivated to become an engineer because a degree in any engineering subject is by no means easy to achieve. If you think you'll spend all your time partying then engineering is definitely not for you.
Finally, you have to do plenty of your own research. Find out about the average AE income, starting income, levels of competition, prospective universities, etc, etc. Research it thouroughly.

7). No. Obviously. I hope you don't just want to become and AE so you can talk to Astronauts?

Guide to CNC Machining Aerospace Parts Efficiently

We evidently see the height of human thought in the design and production of flying machines. From rockets, jets to airplanes, they are all tasking to design, leave alone produce. This is why only a few companies ever opt to dive into the aviation set up. Luckily, Creatingway is among the few out there that work on aerospace parts. We achieve this through our team of experts that are adept in rapid prototyping methods. One common method is CNC machining. An aircraft comprises lots of parts that need to be durable and precise. Ensuring that we machine aerospace parts efficiently allows us to produce top-notch parts.

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What Problem Do We Face when CNC Machining Aerospace Parts?

Precision machining of aerospace parts comes with many concerns. Firstly, the many parts making up a single aircraft arise from an array of materials. The engine, for instance, is one of the most crucial parts that must work properly. We make it from hardened heat-resistant alloys that are tricky to the machine. They are poor conductors of heat and thus prone to temperature build-up when operating. This is because the heat fails to dissipate away. The precision aerospace parts need is usually stricter than in other industries. Moreover, the geometry of its parts is much more tasking to process.

Other than the direct machining problems, there are a few other indirect issues. One of them is named the production standards. Just like in the medical set up, aerospace parts have to meet strict machining standards. The following guide will depict how we machine aerospace parts efficiently.

How to Machine Thin-Walled Aerospace Parts Efficiently

Weight is a vital factor we consider when CNC machining aerospace parts. Lighter aircraft consume less fuel. Our team of experts thus prefers designing aerospace parts with thin lattices, walls, and webs. Initially, we commence machining on a stamped metal block or solid cast. The resultant waste material of such a process is 95%. However, high material wastage is not the main concern in this case. The actual problem is the high cutting force we have to use. This results in deformation when machining such parts. There is a high risk of breaking the thin walls if we raise the feed and cut depth. This arises from the accompanying vibration. We may also end up producing excess heat that deforms the walls. In such a case, we have to cut away tiny chips at a snail’s feeding rate. This raises the total machining time.

Luckily, our team of experts has come up with a way to lower the machining time. This is enabling us to machine thin-walled aerospace parts more efficiently. The first thing we try to do is to lower the vibration. The thin wall may bend or crack after striking it with a vibrating tool. We achieve this by lowering the feeding rate while increasing the number of cutters. We can opt for multiple cutters in a CNC lathe or several cutting edges in a CNC mill. The best cutting method when milling thin-walled aerospace parts is climb milling. It utilizes a feed that moves in the opposite direction from the normal milling method. Climb milling results in a lower cutting force. It also comes with a better surface finish and lower vibration. The lower vibration arises from the fact that the mill enters the material where its wall is thickest. This allows us to machine the part more efficiently.

How to Reduce Overheating of Aerospace Alloys

Overheating of aerospace parts arises from poor heat conduction. Luckily, our team of experts at Creatingway has come up with a way to counter this issue. The machining strategy is trochoidal milling. It uses the ability of CNC machines to trace complex cutting paths. The trochoidal method utilizes a small mill to follow a path identical to a spring projection on a flat surface. The mill cuts after one curve then return on the second curve, which cuts the metal again. This method lowers the time of contact between the tool and material thus allowing it time to cool.

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The technique though has blanker tool runs than normal milling. It luckily negates this by offering increased cutting feeds and speeds. We also offer EDM machining that is much more efficient than precision CNC machining aerospace parts.

Picking the Right Tool for Quick Machining

CNC machines play a big part when it comes to minding the machine tools. This is since it has an array of uses in aluminum machining. One vital way of improving the efficiency of machining is by selecting the right cutting tool. The trick to choosing a tool for any material is trying to counteract its negative properties. In this case, we are dealing with hardened heat-resistant metal alloys. The perfect tool for this case is diamond-cutting tools. They are harder, durable, and cause little vibration. There are also ceramic tools that can work at extremely high temperatures. This helps us improve our efficiency when CNC machining aerospace parts. If you have any inquiries or quotes regarding the machining of aerospace parts, simply contact us.

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