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

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.