FlexiMill

December 12, 2018

A technology platform for the fast machining of freeform surfaces using circle segment end mills

Project start: Aug 2017

Project end: Jul 2019

Details

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.

Partners

Funding agency

UEFISCDI – Executive Agency for Higher education, Reasearch, Development and Innovation Funding

Contract

Contract Nr. 64 / 2017

Value
RON
EUR
Total value from UEFISCDI
618.902,00
135.546,00
Total value (own resources)
577.952,00
126.577,00
Contract Total Value
1.196.854,00
262.123,00

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)

Project Goals

  • 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.)

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