High-volume machining – Maximum efficiency in aluminium machining
In the aerospace industry, due to the costs and weight savings, structural parts that are milled from a solid material are primarily used in an integral design. During this kind of high-volume machining, high demands are placed on component quality and productivity in particular. The proportion of structural parts made of aluminium alloys, along with composites and titanium, makes up the majority of materials used in modern aircraft.
The challenges concerning the high-volume machining of aluminium include high material removal rates and the resulting chip clearance and an optimum utilisation of the machine tool efficiency. The increase of component-and material-specific process settings and tools in high-volume machining provides great potential for productive and economic aluminium machining.
Motivation
The increasing level of air traffic, both in the passenger sector as well as in air freight, requires an estimated increase in transport capacity of up to 5% per year in the coming years (see Figure 1). Tightening of emissions regulations, rising quality standards, and economically and ecologically related resource savings place demands on finding efficient drive solutions, improved aerodynamics and constant weight savings in aircraft.
The increasing proportion of structural parts and increasing cost pressure caused by this lead to increased demands for efficient and highly productive manufacturing. The technological developments of the past 40 years have resulted in a reduction in fuel consumption and CO2 emissions by 70%,in the noise level by 75% and in unburned hydrocarbons by 90% [1] while simultaneously increasing the comfort for passengers.
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