Industry:      Aircraft

  Component:  Landing gear

  Material:       1.2083 ( X42 Cr 13 )

  Machine:       Droop & Rein TF + FOGS

Job title:

Implementation of efficient milling strategies for 3-D-milling in batch production towards process-optimization   

• reduction of cycletime
  
• process reliability
• multiple machine operation
  
• minimizing of retouching work
• avoiding of customized tooling
  
• reduction of tool varieties: cutter bodies, tool holders, cutting materials
  
• no usage of coolant lubricants
• reduction of downtime

• 11 different one's, partly customized milling cutters and tool holders
• stockkeeping, replacement time, replacement costs
  
• limited capability for plunging, starting drill-holes necessary, increased machining time, no multiple machine operation possible
• there is no process-reliability through increased dephts of cut, and reduced manpower is impossible
  
• program-designs are very time-consuming
  
• residual stock is to big for pre-finishing process

• 5 tools only, Pokolm-standard tooling
  
• from stock, short replacement time
  
• all tools capable for plunging, no starting drill-holes necessary
• usage of only 2 different cutting materials
• near net-shape machining, conversion to multiple machine operation
  
• programming standardized
• retouching work cut in half
  
• change-over from drilling to helical milling, no coolant lubricants
  
  

Example from practice
machining:	roughing	finishing
tool:	5 52 300/7 (diam. 52/R8)	35 201 (diam.35/R8)
inserts:	04 16 844, P40	04 16 835, HSC05
coating:	PVML	PVTI
arbor:	100 22 710 (diam. 22/SK50)	75 16 A63 (M16/HSK 63 A)
vf (feed rate):	5000 mm/min	15000 mm/min
n (revulotions):	1200 1/min	12000 1/min
ap (cutting depht):	2 mm	0,5 mm
ae (cutting width):	40 mm	1,5 mm
chipvolume:	400 cm³/min	- - -
	air through spindle	air through spindle
tool life:	2 hours	20 hours