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Drilling of high-strength titan material and composites in combination creates complex challenges in order to achieve required productivity and quality. Long spiral chips are characteristically for the titan drilling process, which leads to e.g. chip accumulation, high thermomechanical load, surface damages and excessive tool wear. The basic approach is the substitution of today’s peck drilling as current solution to this problem and the implementation of a vibration assisted drilling, so called micro-peck-drilling-process, to generate a kinematic chip breakage in a significant more efficient way. To meet perfectly the requirements regarding rates, quality and automation level, Broetje-Automation as system integrator has investigated and developed the implementation of different alternative high-performance systems and methods to approach the optimal oscillation movement of the tool.

For the past ten years, international Aerospace production is asking for flexible and production optimized machinery including IT-Integration packages for streamlining machine tool efforts into aircraft production. As one answer of these questions, a new innovative robot cell has been developed for drilling and fastener insertion in the inner structure of aircraft parts consisting of composite, titanium and aluminum. The new robot cell is based on a scalable 840D system configuration. The required absolute path planning and positioning accuracy force us to integrate our developed compensation methods in the 840D control system. This solution demonstrates how standard robots equipped with a matured control, compensation and off-line programming strategy by an innovative Aerospace solution supplier resulted in a highly flexible and cost-efficient light weight automation response.