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Item type:Publication, Access status: with files , Feeling machines: Prediction of thin-walled workpiece deflection by monitoring variations in tool bending moment pattern during circumferential milling(Elsevier, 2026-06-30); ; ; In circumferential milling, the in-process deflection of thin-walled workpieces induced by feed normal forces results in reduced material removal, leading to geometric errors after machining. With the increasing use of additive manufacturing technologies and the production of near-net-shape structures, this problem is gaining increasing importance. Various strategies attempt to compensate for this geometric errors, for example by modeling the occurring cutting forces and workpiece deflection and then applying countermeasures during machining. However, this requires a high level of process understanding, and multiple parameters need to be considered, including material properties, cutting edge geometry as well as wear state of the tool. This paper examines a novel approach to predict workpiece deflection state by analyzing the bending moment pattern measured by an in-process sensor system located in the tool holder. It could be demonstrated that features extracted and evaluated from the bending moment signal can represent the current deflection state of the workpiece in an offline approach, enabling future in-situ toolpath adaptation to reduce geometric errors without relying on time-consuming simulation of the workpiece stiffness and with minimal signal processing effort.Publicationtype: Journal Article38 16 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Distortion Minimization in the Machining of AM-StructuresAdditive manufacturing offers numerous advantages due to its near-net-shape design and the associated resources savings, but also poses challenges such as residual stresses. These lead to distortion, positional- and dimensional-errors, resulting in scrap or further post-processing. To counteract this, the article compares various alternating milling strategies with conventional approaches to show that the errors can be reduced by over 90 % with a suitable process design.Publicationtype: Journal Article60 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: with files , Control loop based dimensional error compensation for milling of near-net-shaped, thin-walled structures(Springer, 2025); ; ; ; Additive manufacturing has the potential to save resources in the pro-duction of lightweight aerospace structural components made of Ti-6Al-4V. Cur-rently, these components are milled out of plate-material, resulting in up to 95% of the material being converted into chips that can only be downcycled. However, machining near-net-shape parts poses new challenges. For example, commonly used methods such as the “waterline”-path approach, which uses the residual stiff-ness of the plate-material to reduce the deflection of the thin-walls due to process forces, can no longer be applied. In this paper, a dimensional error compensation method is presented, that measures the deflection of the workpiece during helical end mill finishing using eddy current sensors. The sensor values are used within a control loop to adjust the toolpaths width of cut and inclination in real time to minimize dimensional error. Next to adjusting for different compliant states of the workpiece, this method adjusts for increasing tool wear states, that produce higher process forces and thereby larger dimensional errors. The presented compensation is compared to a conventional machining approach to demonstrate its capability to enable finishing of near-net-shape parts within tight tolerances while maintaining high material removal rates.Publicationtype: Conference Paper48 26 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Rattervermeidung beim Fräsen mit IndustrieroboternThe machining of components is usually carried out using specialized machine tools, which shift the stability limit towards high productivity due to their high rigidity and damping. An intelligent design of the end effector promises a positive influence on the stability limit in order to achieve comparable results with more cost-effective industrial robots. This article therefore investigates the influence of different milling spindles and tool concepts on the stability of milling processes on an industrial robot.Publicationtype: Journal Article44 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Characterization of the surface error during peripheral milling of thin-walled, near-net-shaped structures(Springer, 2023-11-18); ; ; ; Lightweight aerospace structural components are usually milled out of plate-material, converting up to 95% of the material into difficult to recycle chips. Therefore, additive-manufacturing holds great resource saving potential through the near-net-shape production of thin-walled parts. However, these parts pose new challenges. For example, previous methods such as the “waterline”-path approach, which uses the residual stiffness of the solid-block to reduce the deformation of the thin-walls due to process forces, can only be applied to a very limited extent. This results in a greater deflection of the near-net-shape, additively-manufactured structure. In this paper the surface error is investigated using milling experiments. An analytical approach to qualitatively predict the surface characteristics is provided. The results get used to discuss whether an adjustment to the tool path is suitable to compensate for the dimensional error. Such a compensation method has the potential to efficiently machine near-net-shape semi-finished parts within the required tolerances.Publicationtype: Conference Paper58 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Dimensional Error Compensation during Finish MillingThere is a limit to productivity when finish milling thin-walled aerospace structural components. Larger engagement conditions lead to deformation of the workpiece, resulting in a permanent dimensional error that does not meet tight tolerance requirements. In this work, sensor technology is used to record the workpiece deformation in the process and derive tool paths that compensate for the dimensional error.Publicationtype: Journal Article42 - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Access status: without files , Robotergeführte spanende Nachbearbeitung additiv hergestellter Großbauteile(Machining Innovations Network e.V., 2023); ; ; Publicationtype: Journal Article32