Characterization of the surface error during peripheral milling of thin-walled, near-net-shaped structures

Volume
Part F1764
Start Page
356
End Page
366
Citation
Congress of the German Academic Association for Production Technology (WGP 2023)
Contribution to Conference
Congress of the German Academic Association for Production Technology, WGP 2023
Publisher DOI
10.1007/978-3-031-47394-4_35
Scopus ID
2-s2.0-85178379238
Publisher
Springer
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.
Subjects
additive manufacturing
milling
surface error
thin-walled structures
DDC Class
620: Engineering