Simultane fünfachsige Fräsbearbeitung von Aluminiumstrukturbauteilen

(Simultaneous five axis milling of structural aluminium parts)

Rautenberg, J.

The continuously increasing demands on the performance of modern lightweight frame structures pose a great challenge for the construction, production and assembly of such components. A highly flexible, small-batch production necessitates the manufacturing of corresponding nodes, which are used for the connection of profiles. Furthermore, a high quality production of the ends of nodes and profiles as well as the machining of the attached contact areas between two joined components is necessary.

Simultaneous five-axis milling was established during the past years due to its high flexibility. Since it is used for the machining of dies and moulds, within the aviation industry and aerospace industry, and for the milling of turbine blades and blisks, it also allows an adequate machining of complex, free-formed lightweight components.

This work shall be a contribution to the machining of complex lightweight connecting elements and joining zones made of aluminium alloys by simultaneous five-axis milling. In order to achieve an adequate surface preparation for the joining methods hydroforming, electromagnetic compression and rolling in, suitable joining zones are identified, the limits of machining are pointed out and the results of surface characteristics on the strength of a joined assembly are analysed. The variation of cutting parameters and strategies and the resulting surface while considering the dynamic behaviour of the machining concept should allow not only a reproducible preparation of surfaces, but also the design of guidelines for construction and machining. Milling simulation systems are additionally used for the analysis and optimisation of selected machining strategies and its results on the surface.

Published as

Dissertation Technische Universität Dortmund, Vulkan Verlag, Essen, 2010, ISBN 978-3-8027-8754-6