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High speed Machining and Assembly

High Speed Machined aluminum parts are replacing built-up parts made by forming and assembly (riveting) in the aerospace industry. The part below was machined on a 5-axis Makino (A77) at Boeing using a 8-15k rpm spindle speed, and a feed of 240 ipm vs 60 ipm conventional machining.

High Speed Machined aluminum parts

This part replaces a build up of 25 parts. A similar example exists for the F/A-18 bulkhead (Boeing, St. Louis) going from 90 pieces (sheetmetal build-up) to 1 piece. High speed machining is able to cut walls to 0.020” (0.51mm) without distortion. Part can be fixtured using “window frame” type fixture.

 
Machine tool Cutter geometry

Software

Number of axes
Spindles
Serial and parallel configurations

Form tool
Cutter radius
Inserts
Tool changers

Flexibilityx
Geometrical compensation
“Look ahead” dynamics compensation


Machine tool, Cutter geometry, Software
 

Simple Classification Scheme for Part Geometry

 
Simple Classification Scheme for Part Geometry