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Development of a dynamic high precision compact milling machine

: Klar, R.; Brecher, C.; Wenzel, C.

Brussel, H. van ; European Society for Precision Engineering and Nanotechnology -EUSPEN-:
10th Anniversary International Conference of the European Society for Precision Engineering and Nanotechnology 2008. Proceedings. Vol.1 : May 18th - May 22nd 2008, Zürich, Switzerland
Bedford: Euspen, 2008
ISBN: 978-0-9553082-5-3
European Society for Precision Engineering and Nanotechnology (EUSPEN International Conference) <10, 2008, Zürich>
Fraunhofer IPT ()
Fräsmaschine; Freiformfläche; Spritzgießverfahren; Präzisionstechnik; Spindeldrehzahl; Direktantrieb; Kontrolleinrichtung; Genauigkeit; Verfahrensparameter; dynamisches Verhalten; Flächenbedarf

The supply of ideal process parameters is essentially needed for highest shape and surface requirements in high precision machining. Especially while machining complex freeform shapes of small and high precise mould inserts for injection moulding the use of at least three axes is necessaiy. Conventional high precision machines using the miniature milling process because of its very flexible ability to machine three dimensional geometries have become a very popular manufacturing technology. Due to the used drive systems conventional machines can not provide the needed dynamics while cutting similarly with all machine axes. To obtain the optimal chip thickness the spindle speed has to be decreased dramatically due to the lack of sufficient path feed. A promising alternative attempt to improve the path feed at highest precision and dynamics is the use of linear direct drives in all machine axes in combination with impulse decoupling systems. This paper presented the development of a compact milling machine requiring 1 m2 floor space. The machine tool represent novel design and control approaches in the field of micro milling to provide highest accuracy and optimized process parameters. Regarding the demands of micro milling of free-form surfaces, a design with integrated impulse decoupling units in all axes was presented, providing highest jerks for continuous optimized path speeds. In the future, the machine tool will be charactereized regarding the precision at high path speeds and machining tests will be performed.