Review of Sensor-Based Approach to Reliable High Speed Machining at Boeing – A Tribute to Jan Jeppsson

Jan Jeppsson was the key architect of a sensor-based system for reliable implementation of High Speed Machining technologies at Boeing Commercial Airplane Group, resulting in substantial increase in productivity in addition to significant cost reduction. Mr. Jeppsson retired from Boeing in 2003 and passed away on December 31, 2012. In memory of his ingenious contributions to high speed end milling technologies in a real production environment, we present this review paper based on his papers and patents. This paper starts with the chatter and control problems encountered in machining commercial airplane structural components, which could be over 100 ft long, using spindles at speeds over 50,000 rpm and end mills over one inch in diameter and axial length exceeding four inches. Mr. Jeppsson developed a software system, Machining Prediction Software (MPS), to identify chatter-free machining windows for different combinations of tools, machine structures, and spindle speeds. The sensor-based milling control system, denoted as the Jeppsson Controller, is used to achieve highest material removal rate with minimal risk of tool breakages and spindle bearings failures. This paper concludes with tributes from Mr. Jeppsson’s co-workers at Boeing, testifying to his character and integrity as a visionary, a mentor, and a leader.