Contents Keynote Speeches 1 Manufacturing of Aero Engine Components - Challenges and Trends 2 Dr.-Ing. Gregor Kappmeyer, Rolls-Royce Deutschland Ltd. & Co. KG Aerospace Machining - Today and Tomorrow 16 Dr. Liangji Xu, The Boeing Company Evening Speech 31 Innovative Manufacturing Projects in Clean Sky 32 Guiseppe Pagnano, Clean Sky Joint Undertaking Session 1 - Manufacturing Technology 57 Digital Tool Data 4.0 - Cost and Benefit for Users and Manufacturers 58 Dr.-Ing. Claus Itterheim, ISBE GmbH High Performance Machining in Titanium Components 78 Werner Penkert, Kennametal Shared Services GmbH Machining of Titanium and Aluminum Parts for the F-35 108 Dr. Alf Pettersen, Kongsberg Defence & Aerospace AS Manufacturing Engineering Efforts toward Aero-Engine Components 122 Makoto Yamasaki, Mitsubishi Heavy Industries Ltd. Special Toolholders reduce Manufacturing Costs 136 Ulrich Zierer, Bilz Werkzeugfabrik GmbH & Co. KG Innovative Machining Strategies for Aerospace Components 150 Markus Heuwinkel, Walter AG Machining Innovations Conference 2014 Session 2 - Scientific Presentations 171 Machinability of Titanium Alloys 172 Professor Pedro Arrazola, Mondragon University Machining of Carbon Fibre Reinforced Plastics 194 E. Uhlmann, F. Sammler, S. Richarz & F. Heitmüller, IWF & IPK, TU Berlin Presentation of a Novel “Simultaneous Three Axis Turning” Process 206 F. Degen, F. Klocke & T. Bergs, Fraunhofer IPT, WZL Aachen Drilling of Inconel 718 with Geometry Optimized Twist Drills 216 N. Beer, E. Oezkaya & D. Biermann, ISF, TU Dortmund On-Machine Tool Resharpening for Dry Machining of Aluminum Alloys 226 T. Sugihara, Y. Nishimoto & T. Enomoto, Department of Mechanical Engineering, Osaka University Quality of Drilled and Milled Rivet Holes in Carbon Fiber Reinforced Plastics 240 J.C. Aurich, B. Kirsch, C. Müller & L. Heberger, FBK, TU Kaiserslautern Influence of Clamping Systems during Milling of Carbon Fiber Reinforced Composites 248 S. Klotz, F. Zanger & V. Schulze, wbk, Karlsruhe Institute of Technology A New Approach to Build a Heat Flux Model of Milling Processes 258 J. Löhe & M.F. Zäh, iwb, TU München Analysis of Material Weakening in CFRP after a Drilling Operation 270 M. Henerichs, R. Voß, H. Tanaka, F. Kuster & K. Wegener, IWF, ETH Zurich Milling and Turning of Titanium Aluminides by Using Minimum Quantity Lubrication 280 P.C. Priarone, M. Robiglio, L. Settineri & V. Tebaldo, DIGEP, Politecnico di Torino Session 3 - Machine Tool Technology 293 New Technologies for the Production of Complex Aerospace Parts: Process Characterization and Metrology, Sacrificial Preforms and Hybrid Processes 294 Prof. Scott Smith, UNC Charlotte Manufacturing Research at NASA for Improved Performance and Reduced Cost 310 Craig Brice, NASA, Langley Research Center Ecospeed - A new Solution for the Machining of Large Wing Skins 324 Dr.-Ing. Norbert Hennes, Dörries Scharmann Technology GmbH (Starrag Group) Frequency-selective Acoustic Emission Analysis for Aerospace Applications: The perfect Machining, Staking and Rapid Prototyping Process 332 Dr. Peter-Christian Zinn, QASS GmbH Aerosol Dry Lubrication (ATS) - an Innovation for New Standards in Machining 340 Reiner Rother, Rother Technologie GmbH & Co. KG Session 4 - Virtual Production 353 An Interdisciplinary Approach to Aircraft Regeneration 354 Prof. Dr.-Ing. Jörg Seume, TFD, Leibniz Universität Hannover Adaptive Machining Applications in Gas Turbine Component Manufacture and Repair 364 Rob Pope, TTL Tool Path Optimization Strategies for Aerospace Parts 374 Jean-Marc Cauzac, Dassault Systems Simulation Based Process Optimization in Machining 388 Dr.-Ing. Volker Böß, IFW, Leibniz Universität Hannover New Challenges and Approaches for Adaptive Machining in Aeronautical Industry 400 Dr.-Ing. Claus Bremer, BCT Steuerungs- und DV-Systeme GmbH Real Advantages of Virtual Production 416 Eberhard Beck, Index-Werke GmbH & Co. KG Machining Innovations Conference 2014 Development of a CAM-Solution suited for Robot Milling in the Environment of the Conventional CAD/CAM System 426 Lars Windels, SWMS Systemtechtechnik Ingenieurgesellschaft mbH Postersession - Scientific Presentations in Aerospace Industry 441 Modelling and Simulation of Laser Assisted Milling Process of Titanium Alloy 442 C. Liu & Y. Shi, Nanjing University of Aeronautics & Astronautics Tool Life Time Extension with Nano-Crystalline Diamond Coatings for Drilling CFRP 444 M. Henerichs, R. Voß, D. Harsch, F. Kuster & K. Wegener, IWF, ETH Zurich Influence of Tool Wear on Quality Criteria for Refill Friction Stir Spot Welding (RFSSW) Process 446 T. Montag, J.P. Wulfsberg, H. Hameister & R. Marschner, LaFT, Helmut Schmidt University Helical Milling of CFRP Using Ultrasonic Vibration and Liquid Nitrogen 448 T. Ishida, K. Noma; Y. Kakinuma, T. Aoyama & S. Hamada, Keio University & Taga Electric Co. Ltd Planning the Regeneration Processes of Complex Capital Goods 450 F. Herde, C. Kellenbrink, S. C. Eickemeyer, T. Kuprat & P. Nyhuis, PROD & IFA, Leibniz Universität Hannover Determination of Residual Stresses in Plate Material by Layer Removal with Machine-integrated Measurement 452 S. Dreier & B. Denkena, IFW, Leibniz Universität Hannover A Mechanistic Approach to Model Cutting Forces in Drilling with Indexable Inserts 454 A. Parsian, M. Magnevall, T. Beno & M. Eynian, AB Sandvik Coromant & University West Energy Efficient Machining with Optimized Inner Coolant Lubricant Flow Rates 456 B. Denkena, P. Helmecke & L. Hülsemeyer, IFW, Leibniz Universität Hannover Influence of Process Temperature on Hardness of Friction Stir Welded High Strength Aluminum Alloys for Aerospace Applications 458 S. Sünger, M. Kreissle, M. Kahnert & M. F. Zäh, iwb, TU München Conceptual Design for Electromagnetic Guided Rotary Table in Machine Tools 460 T. Brühne, B. Denkena, D. Dahlmann & F. Flöter, IFW, Leibniz Universität Hannover Experimental Investigations on Sinking-EDM of Seal Slots in Gamma Titanium Aluminides 462 F. Klocke, M. Holsten, L. Hensgen & A. Klink, WZL, RWTH Aachen University Quality Assessment through In-process Monitoring of Wire-EDM for Fir Tree Slot Production 464 F. Klocke, D. Welling, A. Klink & R. Perez, WZL, RWTH Aachen University & GFMS Agie Charmilles SA Optical In Situ Measurements and Interdisciplinary Modeling of the Electrochemical Sinking Process of Inconel 718 466 F. Klocke, M. Zeis, T. Herrig, S. Harst & A. Klink, WZL, RWTH Aachen Universityweiterlesen