Difficult-to-machine materials are still challenging the production industry. Examples are highly complex components of aircraft engines. Alongside innovative processes, also improved machine tool components are helping to comply with the demands of this task. This paper presents a design approach of a rotary table with an active magnetic bearing. Opportunities in machining through employing magnetic guides are presented and discussed in the beginning. In the following, a workflow for the magnetic bearing design in swivel rotary tables is proposed. The mentioned steps are executed based on a presently under design rotary table.
Re-contouring in the repair process of aircraft engine blades and vanes is a crucial task. Highest demands are made on the geometrical accuracy as well as on the machined surface of the part. Complexity rises even more due to the unique part characteristic originating from the operation and repair history. This requires well-designed processes and machine tool technologies. In this paper, approaches for coping with these challenges and improving the re-contouring process are described and discussed. This includes an advanced process simulation with its capabilities to accurately depict different material areas and predict process forces. Beyond, experimental investigations on workpiece-tooldeflection are presented. Finally, a machine tool prototype with a novel electromagnetic guiding system is introduced and the benefits of this technology in the field of repair are outlined.
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