Product Code: ICA12_1306

Fundamental Investigations and a System Technology for Laser-Assisted Milling of Titanium Alloys
Authors:
Robert Wiedenmann, Technische Univ. Muenchen, Institute for Machine Tools and Industrial Management (iwb); Garching Germany
Michael Zaeh, Technische Univ. Muenchen, Institute for Machine Tools and Industrial Management (iwb); Garching Germany
Presented at ICALEO 2012

Conventional steel materials are more and more substituted for advanced materials like titanium alloys for lightweight constructions and high-performance components. Especially in aerospace applications this trend is very distinctive. The newest generation of aircrafts consists of up to 20 % titanium alloys. Compared to other materials the physical and chemical properties of titanium are advantageous. But the machining process is a very cost-intensive manufacturing step as high production times and costs respectively complicate an economic machining process. This paper presents the investigations of the hybrid process achieved in the project Laser-Assisted Milling of Advanced Materials. Also a prototype of a machine, which is developed together with industrial partners, is showcased. Fundamental investigations proved that the process forces can be reduced by up to 20 % and the material removal can be increased by up to 35 % by the chosen strategy of laser-assistance in comparison to a conventional milling process. A conventional milling machine was upgraded with necessary laser safety measures and a fourth NC-axis to control the laser integration. In addition a CAD/CAM process control unit, which is essential for an industrial application, was developed.