The theoretical part of the thesis deals with materials used in the aircraft industry with a focus on aluminium alloys. Then it describes high speed machining, its characteristics and its comparison with conventional machining. The following chapters describe strategies of machining thin-walled parts and a description of vibration that occurs during machining. The practical part deals with selection appropriate tool geometry, machining of thin-walled parts and evaluation of their deflection during machining.

This master’s thesis has been elaborated as a part of master’s studies of engineering technology M2I-K, major in M-STM – Engineering technology and industrial management and deals with the problem of a transition to a self-production of previously purchased distance washers. Distance washers were purchased in six different types of similar shape, each type in four different thicknesses. One of these types was chosen as a representative for this master’s thesis. We shall explore the possibilities of self-production with the emphasis on economical validation of the transition. The distance washer is a flat part, the intermediate being sheet metal. Technologies considered for manufacturing the washers correspond to the technical facilities and equipment available at the production hall of the company this project is planned for. The company possesses technology for CO2 laser cutting, cutting by CNC punching machine and cutting in the punching tool. To provide a complex overview we shall also enquire into cooperated technologies such as water jet and plasma cutting, oxy-acetyleny cutting and CNC working. All options are evaluated with regard to the production expenses and lead to a most economically plausible method of manufacturing or, if need be, give reasons for going back to purchasing the part from the current supplier.

Since aircrafts manufacturers intend to produce low consumption and efficient aircrafts, parts become more and more difficult to machine. Some processes like „air machining“ enables a one-step production for complex aluminium alloy shaped parts. Although the assembly offers a large access to cutting tool, the lack of stiffness for large parts, and especially for thin-walled aeronautics parts implies strong vibrations during machining. The aim of the study is to solve these difficulties in order to keep productivity and improve surface quality. Further innovative solutions are considered like modal analysis, in-phase machining, spindle speed variation, 3 flutes end mill and variable helix angle mill. All propositions are tested on DMG 65 machine tool with Siemens 840D controller. Although vibrations are intrinsic to flexible parts, surface quality has been improved with higher cutting continuity and variable helix angle cutting tool.

The diploma thesis is concerned with evaluation of actual production technology of part “hydraulics cover” and with design of new, progressive variation machining of this part. Solution is focused at first on rationalization of cutting tools and choice of suitable cutting tools. An effort is to achieve shorter production time and decrease costs on production of component. With this problem is related alteration of technological documentation and technical economic evaluation for determination return rate of investments into progressive cutting tools.

This thesis describes the methods and procedures used in designing production lines, focusing on the production line for machining of train wheels. The thesis also describes the basic types of railway wheels, their design and important design elements. It also deals with the complete manufacturing process of train wheel from material selection through the technological processes of forming, heat treatment, mechanical tests, machining and non-destructive testing and measuring. Suitable equipment for the construction of automatic lines for machining, inspection and measurement of train wheels is selected according to the specified parameters of the wheel types, manufacturing productivity and production shop dimensions, These devices include vertical machining center, single-purpose machine for grease outlet drilling, device for ultrasonic inspection, magnetic particle inspecton device, measuring station and train wheel balancing machine. Several variants of the production line including detailed specification of manipulation cycle times is created. These variants are mutually compared and evaluated to find the optimal solution.