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  1. bookVolume 16 (2022): Issue 1 (March 2022)
Acta Mechanica et Automatica's Cover Image
Acta Mechanica et Automatica
Journal Details
Format
Journal
eISSN
2300-5319
First Published
22 Jan 2014
Publication timeframe
4 times per year
Languages
English
access type Open Access

Using HSM Technology in Machining of Thin-Walled Aircraft Structures

Paweł Bałon,
Paweł Bałon,
Edward Rejman,
Edward Rejman,
Bartłomiej Kiełbasa and
Bartłomiej Kiełbasa and
Robert Smusz
Robert Smusz
Published Online: 04 Feb 2022
Volume & Issue: Volume 16 (2022) - Issue 1 (March 2022)
Page range: 27 - 33
Received: 06 Jul 2021
Accepted: 05 Oct 2021
Acta Mechanica et Automatica's Cover Image
Acta Mechanica et Automatica
Journal Details
Format
Journal
eISSN
2300-5319
First Published
22 Jan 2014
Publication timeframe
4 times per year
Languages
English
Abstract

Subtracting manufacturing technologies have entered that realm of production possibilities which, even a few years ago, could not be directly adapted to direct production conditions. The current machines, i.e. heavy, rigid cutting machines using high spindle speed and high feed speed, allow for manufacturing very thin and relatively long parts for use in the automotive or aerospace industry. In addition, the introduction and implementation of new 70XX aluminium alloys with high strength parameters, as well as monolithic diamond cutting tools for special machining, have had a significant impact on the introduction of high-speed machining (HSM) technologies. The main advantage of the applied manufacturing method is obtaining a very good smoothness and surface roughness, reaching even Sz = 6–10 μm and Sa <3 μm, and about four times faster and more efficient machining compared to conventional machining (for the beam part). Moreover, fixed and repeatable milling process of the HSM method, reduction of operational control, easy assembly of components and increase in the finishing efficiency compared to other methods of plastic processing (forming) are other benefits. The authors present a method using HSM for the manufacturing of aircraft parts, such as the chassis beam at the front of a commuter aircraft. The chassis beam assembly is made of two parts, front and rear, which – through a bolted connection – form a complete element replacing the previous part made using traditional technology, i.e., cavity machining, bending and plastic forming. The implementation of HSM technology eliminates many operations related to the construction of components, assembling the components (riveting) and additional controls during construction and assembly.

Keywords

  • aviation
  • high-speed machining
  • milling
  • thin-walled parts
  • integral structures

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