Horizontal 5-axis machining centre

• Subject Area: Production Technology
• Term: Funded in 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 469991284

New concepts in the field of energy generation and the consistent increase in resource efficiency in the field of aviation increasingly require research into process chains for the production of large and at the same time very precise components such as large gears, structural components or turbomachine components. The machining of components made of difficult-to-machine materials and components with the highest precision requirements has been a focus of research at the WZL of RWTH Aachen University for many years. However, fundamental findings from this work cannot be easily transferred to large machines and the machining of larger components from the areas mentioned. One reason for this is the mechanical, thermal and dynamic process properties when machining these components, which often do not behave linearly to the component size and accordingly cannot be scaled up from smaller components. For process optimisation in the production of large components, the technological system of large machines, which has unique properties compared to smaller machines, must also be taken into account. For example, large machines, like the component, have fundamentally different thermal, mechanical and dynamic behaviour due to their larger masses, higher natural frequencies, increased drive power, different designs, kinematics and increased travel distances. Nevertheless, they have to achieve similar accuracy requirements in the single-digit micrometre range at significantly higher cutting rates. This behaviour can only be investigated on the basis of a large machine, and in particular on one that has a universal and far-reaching performance spectrum. The following line of argument is followed in the proposal: Chapter 3 sets out for the individual working groups which research projects related to large component manufacturing and 5-axis large machining centres are to be carried out in the next few years. Based on these research projects, quantifiable machine-specific requirements are derived and reasons are given as to why certain machine characteristics are necessary. Finally, in Chapter 4, the favoured machine configuration is delineated from alternative machines on a technological level and thus its uniqueness in relation to the requirements set is elaborated.

• DFG Programme: Major Research Instrumentation
• Major Instrumentation: Horizontales 5-Achsen Bearbeitungszentrum
• Instrumentation Group: 2030 Fräsmaschinen
• Applicant Institution: Rheinisch-Westfälische Technische Hochschule Aachen
• Leader: Professor Dr.-Ing. Thomas Bergs