A technology platform for the fast machining of freeform surfaces using circle segment end mills
Project start: Aug 2017
Project end: Jul 2019
The aim of the FlexiMill project is to develop a turnkey technology platform for making novel and superior circle-segment-end-mills (also known as “barrel-tools”) for milling complex parts. Using circle-segment-end-mills significantly increases the flexibility and productivity of industrial milling processes (>400% productivity). The technology platform uses a threefold approach, combining the development of optimized tools, software and process knowledge.
Contract Nr. 64 / 2017
Total value from UEFISCDI
Total value (own resources)
Contract Total Value
Further Project Details
The proposed project (FlexiMILL) aims to develop a turnkey ready technology platform to make novel and superior circle-segment-end-mills (also known as “barrel-tools”) usable in the milling of complex parts. By using circle-segment-end-mills the flexibility and productivity of industrial milling processes can be increased significantly (>400% productivity). The technology platform encompasses a threefold approach, combining the development of optimized tools, software and process knowledge.
The manufacturing of geometrically complex products with freeform surfaces is often done by extensive 5-axis-machining operations. 5-axis-machining of freeform surfaces (roughing, finishing) with state-of-the-art ball-end-mills is very time intensive though. Circle-segment-end-mills can reduce cutting time by 78%. However, a reliable and efficient use of those mills for the machining of complex geometries is not possible though as a technical turnkey ready solution is missing yet.
The FlexiMILL technology platform will be sold twofold:
- Exploitation of optimized, superior circle-segment-end-mills (hardware)
- Exploitation of process-planning and machining knowledge (CAM-software)
- Significantly increased geometric flexibility in circle segment end milling
- Reduced manufacturing time of milled parts between 40%-60% at the same surface quality
- Increased surface quality of milled parts between 60%-80% at the same machining time
- Reduced overall manufacturing costs of milled parts between 20%-30%
- Reduced tool consumption and tool costs (applied tools can be used more efficiently)
- Reduced unproductive tool changes
- Reduced waste and reduced consumption of rare resources (carbides, coolant, energy, etc.)