On the Advanced Milling Technology of Thin-Walled Parts for Aerospace Industry

This paper is focused on advanced analysis of a progressive milling technology of high strength alumina alloy 7475-T7351 that is used in modern aerospace industry today. The analyses comprises a study of the material, its mechanical properties, use of alternative monolithic-carbide tool designs, micro-geometries of the milling cutters, coatings and a study of cutting parameters on dynamics of cutting , its productivity, quality of the surfaces and other specific cutting phenomena. This work includes an experimental verification of the proposed technology using 5-axis CNC machining centre, evaluation of 2D/3D surface structures using optical high-resolution 3D surface device. Dynamometer Kistler 9575B/SW DynoWare were used for measuring of instantaneous force loading in long time series. The results are relevant for milling of thin-walled parts and the up and down milling strategies without any other surface treatment of the parts. Some fatigue studies are in progress.