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Enhancement in the precision of high-speed milling of complex parts

December 14, 2005

The research team led by Norberto López de La Calle at the Department of Mechanical Engineering at the University of the Basque Country, have designed a new model for optimising the high-speed, 3- or 5- axis milling of complex parts. One of the objectives in this field has been the development of a methodology for the a priori estimation of errors due to flexion of the milling-machine housing system given that some errors, induced by cutting forces, lead to non-compliance with the tolerances of certain applications such as plastic or aluminium injection moulds, precision matrixes and the and the teeth of turbines and compressors.

Now there is available a module that operates with CAM and enables the selection of those milling trajectories, whether in 3- or 5-axes, that minimise the force producing the error. The final result is a saving in milling time and greater added value of the manufactured tools.

The value of this field of research has been tested with applications in a number of moulding and matrix companies.

Currently the research group is continuing with this research within the framework of the MARGUNE Cooperative Research Centre and the state-wide technological network for High-Yield R2-TAF Manufacture. Moreover, parallel lines are being worked on such as the milling of reduced-rigidity aeronautic items and non-conventional processes (laser, deposition, EDM) in cooperation with other bodies. The research team has at its disposal two machines with this technology (2000+ rpm screws), one with five simultaneous axes and advanced equipment for carrying out and monitoring milling tests.

Elhuyar Fundazioa