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of such parameters as: friction, tool geometry and holding down force on the strain and stress distribution.
The simulation results will be compared with the experimental ones. The numerical simulation will be carried
out with the ADINA System based on the finite element methods (MES).
Title: The New Economic Feasibility of Titanium Machining
Authors: U. Speetzen, L. Castellano
Makino GmbH
Time: November 3, 2009 2:00 pm
Room: Candela
With the aim of creating intelligent lightweight structures, modern aircraft manufacturing has become focused
on continuously updating its construction materials. Due to the rapid growth of composites as a structural
material, the number of Titanium structural parts in aircraft construction has also increased. The reason for
combining titanium and carbon fiber lies in the low electro-chemical difference between the two materials, in
comparison to the combination of aluminium and carbon fiber.
Moreover, titanium alloys are regarded among the most preferred construction materials due to their light
weight as well as their high tensile strength characteristics. When compared to other materials, titanium also
demands completely different tool and machine characteristics due to the high cutting load, torque and the
extreme temperatures that are created at the cutting edge. The economical feasibility of titanium machining
can only be achieved through a holistic view of the complete process chain. Thanks to years of experience in
titanium and aluminium structural parts machining, MAKINO has created a new family of machines specifically
designed for the machining of titanium.
The challenge: roughing and finishing Titanium structural parts on a 5 axis machine.
This challenge however is not new. Indeed, 5 axis simultaneous machining for finishing operations is already
commonly used and there are many machines which can perform high demanding roughings in 3-axis movements.
Therefore, MAKINO brought the challenge one step further.
The new concept: improving the efficiency of the cutting process by performing not only finishing operations
but also highly demanding roughing operations with simultaneous 5-axis machining. This approach demands
new levels of performance from both the machine and cutting-tool.
The solution: a compact horizontal machining centre featuring a revolutionary spindle head which allows not
only simultaneous 5-axis cutting but also utilizes high pressure / volume coolant directly through the spindle.
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The application: utilization of innovative tooling technology and process strategies.
The result: four times more productivity than conventional machining, not only with regards to machining times
but also to the final cost of produced parts.
Title: A new concept of rivet proposed to use in aeronautical constructions
Authors: Dr T. Balawender, Prof. R. E. Sliwa
Rzeszow University of Technology
Time: November 3, 2009 2:20 pm
Room: Candela
The new rivet construction has been analysed and proposed to apply for aeronautical use. The rivet is made
up of two parts. Each part consists of head and shank but one shank is in form of a pin and another is in form
of a sleeve. Closing up of rivet consist in joining of these two rivet parts. Joining is the consequence of plastic
deformation of constituent rivet shanks. No rivet head plastic forming is performed during clenching process,
so it can be accurately controlled by displacement of dies. When the rivets are compressed, the diameter of
the pin shank grows and forces the deformation of the second rivet shank (sleeve) until the rivet hole is completely
filled. Because the pin deformation leads to barrel-shaped resulting from non-homogeneous deformation ,
the initial outer shape of the sleeve is in the form of concave cylinder; inner shape of sleeve is matched to the
pin cylindrical shape. At the end of compressing process this concave shape is straighten to cylindrical hole
shape but because of pin barrelling the inner shape of sleeve becomes concave. This concave curvature of pin
–sleeve shank surface gives the effect of the rivet shut.
The results of the first step of new rivet investigations have been realised. Two different materials (aluminium
and copper) were used for constituent rivets. The obtained results of good connection investigated under different
conditions have been presented.
Title: Forming of Titanium Alloys
Authors: W. Beck, W. G. Jung, S. Arends
FormTech GmbH, Weyhe, Germany
Time: November 3, 2009 2:40 pm
Room: Candela
Titanium alloys are badly desired for aircraft from the stress calculation and weight saving point of view. Titanium
alloys exhibit an extraordinary favourable combination of low specific weight, high strength and corrosion
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