A revolution in complex manufacturing solutions

A revolution in complex manufacturing solutions
A revolution in complex manufacturing solutions

Michael Kirbach, head of the DMG MORI Aerospace Excellence Centre, talks about manufacturing complex aviation component challenges and how DMG MORI is facing them with ongoing development work.

In a Q&A session, The aviation industry has been in a state of upheaval for some years now: ever-increasing fuel costs and calls for lower CO2 emissions are forcing manufacturers to invest in more efficient and environmentally-friendly aircraft. This is posing entirely new challenges in terms of manufacturing complex aviation components. According to forecasts, the global fleet of passenger and cargo aircraft will double in the next 20 years which, factoring in the necessary replacements for old aircraft will result in the need for more than 30,000 new aircraft. Q: What is the reason for the state of constant change in the aviation industry? With lightweight engineering featuring carbon fibre-reinforced plastic (CFRP), the Boeing Dreamliner and the Airbus A350 XWB represent an initial response to the growing economic and technological challenges in the aviation industry. Large volumes of orders for other fuel-saving models such as the Airbus A320neo and the Boeing 737 MAX with new engines and a few new concepts attest to a change of thinking, even for short and medium-distance flights. Q: What sets these new aircraft apart? One major factor these aircraft have in common is the use of extremely light yet highly resilient materials, such as the increased use of titanium alloys and CFRP. The temperatures in the engines are increasing in order to reduce emissions, which in turn make these materials more challenging. To be able to machine these efficiently requires expertise and cutting-edge machine tool technology. Q: You focus on such applications at the DMG MORI Aerospace Excellence Centre. What is your goal here? For us, it is a matter of using our experience and technological expertise to gauge the individual needs of aerospace customers and develop perfectly coordinated, flexible and reliable manufacturing processes for each component on the basis of our wide range of products. Ultimately, manufacturing costs today have to be adapted to much shorter life cycles than in the past. Q: What exactly is in your range of services for customers? The work can start with a technical consultation and lead to turnkey solutions which we can design to meet the specifications of the customer. Turnkey projects in particular require an extremely holistic approach: they encompass the machine tool, specific machine equipment, a component-specific selection of tools, clamping devices, NC programs and integrated quality control. The entire system is set up for the user on site so that, following delivery, it is ready to manufacture reliably and efficiently from day one. Q: From the perspective of manufacturing, what do you think are the most significant trends in the aviation industry? Lightweight engineering, which I have already mentioned, is far in front. Complex aluminium structural parts are milled from solid metal. The demand for titanium components is also growing due to the increasing use of composite materials. DMG MORI achieves the high material removal rate and the necessary level of precision with options such as the heavy-duty machining package. This consists of extra hydraulic sliding damper shoes on the linear axes in combination with a powerful geared spindle with up to 1,100Nm torque, or even the new Powermaster motor spindle rated at up to 700Nm (40% DC). Independently developed precision measures lead to higher position tolerance which facilitates reliable, efficient production in one set-up with 5-axis simultaneous machining. Q: What is the value of automation solutions in this context? The automation of machining processes with process monitoring and in-process measurement reduces the level of risk in manufacturing, which can then be made even more productive with additional automated handling elements such as pallet changers and even fully automated flexible manufacturing cells. Q: Lightweight engineering also involves the use of fibre-reinforced composites. What does this mean for your work? Besides the mass production of CFRP components, demand will grow for an automated, efficient method of post-machining, maintaining and repairing damaged fibre composite. Our process approach is based on innovative ULTRASONIC technology which makes it possible to machine these high-performance materials extremely efficiently and in optimal component quality. In milling supported by ultrasonic technology, the tool rotation is combined with a patented inductive ULTRASONIC actuator system with additional oscillating longitudinal movement kinematics. This cuts process forces by up to 40%, produces cleaner edges and prevents fibre fraying and delamination. Based on recent findings, ULTRASONIC technology can also reach feed rates of more than 12m/min and solid carbide tool service lives of over 600m. Q: How does the future of manufacturing in the aviation industry look for DMG MORI? As plans in the field of aviation technology are made far in advance, DMG MORI will rely on foresight and extremely advanced production solutions. This is the only way to ensure that everyone involved remains competitive in the long-term. To this end, we are continuously working on innovative processes which could revolutionise the market. One of our most recent developments is the integration of laser deposition welding into the machine tool, for example the LASERTEC 65 3D and the LASERTEC 4300 3D. What makes these developments unique is that they combine laser deposition welding and machining through 5-axis milling or turning, making it possible to manufacture and repair highly complex components in one set-up on one machine. This makes it possible, for example, to realise numerous 3D geometries with undercuts and then machine them in five axes with no limits. This will provide more freedom to create new geometries, not to mention flexibility and ways to boost productivity, such as during repair work, which always used to be inconceivable. www.dmgmori.com

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