<p>The machining deformation of thin-walled aerospace components presents a significant challenge in aviation manufacturing. Current methods to address the deformation issues in the split-fairing frame component (SFFC) are inadequate. This study introduces a machining deformation control technique based on the analysis of stress-sensitive regions. The technique employs a finite element simulation to apply residual stress across the mesh units on the machined surface of a component and evaluates the effects of machining its various regions and their stress states on the component’s critical dimensions, thereby identifying the stress-sensitive regions and their corresponding directions. Based on the identified stress-sensitive regions, the machining sequence for the component is established, and the machining path is optimized according to the identified stress-sensitive directions. By integrating these findings with enhancements in the machining process parameters of the component, its deformation is minimized, ensuring that the quality of the component fulfills the required accuracy standards. The effectiveness of the optimized machining process in reducing deformation and achieving high machining accuracy is demonstrated through comparative experimental analysis. The application of this method ensures the precision of several critical dimensions of the SFFC and enhances the one-time machining qualification rate of the components. This approach saves time and resources and enhances the accuracy of subsequent assembly processes for the components.</p>