Transcript Folie 1

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WHO IS IRUBA INNOVATIONS?
INNOVATIONS & IDEAS
RUTSCHINSKI MATTIAS - Face and CEO
BAUER JOACHIM – Tool head and CEO
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI
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WHO IS IRUBA INNOVATIONS?
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Founded 1. August 2009 -GbR / 2013 -GmbH
Tools are only made at the J. Bauer GmbH
Specials are our specialty (accuracy / design/ form
IRUBA offers solutions
2012 start of strong collaboration with DPS
(Delcam professional services UK)
- 2014 several new Partner to complete solutions
PATENTED TECHNOLOGY
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INNOVATIVE GREEN TECHNOLOGY
MANUFACTURING OF
FIR-TREE-ROOT NOTCHES
GERMAN ENGINEERING / PATENT
TOOLS MADE IN GERMANY
CARBIDE MADE IN GERMANY
GERMAN SUPPORT WORLDWIDE
REMANUFACTURING OF TOOL IN GERMANY
PATENTED TECHNOLOGY
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NEW WAYS
BETTER SOLUTIONS
INNOVATIONS
NEW TECHNOLOGIES
PATENTED TECHNOLOGY
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THE IDEA FOR THE NEW TECHNOLOGY
1.
PATENTED TECHNOLOGY
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3.
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BASICS OF THE NEW TECHNOLOGY
A ROUGHING OPERATION
- WITH HIGH THERMAL DEVELOPMENT
- BIG CUTTING FORCES
- LOW CHIP-REMOVAL-RATES
WILL CHANGE INTO A „FINISH OPERATION“
- WITH LOWEST THERMAL DEVELOPMENT
- LOW CUTTING FORCES
- HIGH CHIP REMOVAL RATES
PATENTED TECHNOLOGY
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BASICS OF THE NEW TECHNOLOGY
Special carbide
end mill
Low cutting forces,
almost no thermal
development on the
cutting edge
Interpolating
high performance
cutting with
only “3“ levels
Open the slot -and put in the undercut
geometry, will be performed in one single
step
PATENTED TECHNOLOGY
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BASICS OF THE NEW TECHNOLOGY
Interpolating
by HPC to
manufacture
notches on a
rotor
END -MILL
PATENTED TECHNOLOGY
Straight notches,
Ankle notches,
Radius notches,
Always
rough-milling
without full
enlacement
FIR -TREE -ROOT NOTCHES
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BASICS OF THE NEW TECHNOLOGY
Advantages:
1.
2.
3.
4.
5.
6.
PATENTED TECHNOLOGY
Highest process safety
No thermal contribution into
boundary layer of work piece
Lowest cutting forces (low KW
Low amount of carbide special
tools
High chip removal rate (Q/min)
Short manufacturing time
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ADVANTAGES OF THE NEW TECHNOLOGY
This new technology can also be used as a
save process to cut super alloys like Inconel or
Titanium alloys.
Only necessary change:
Parameters, NC program, Adopted tools
PATENTED TECHNOLOGY
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ADVANTAGES OF THE NEW TECHNOLOGY
-With one set of tool for defined geometry,
all kinds of notch forms can be machined.
-No limitations!
-Down- cut or up- cut milling operation for
the final tool.
-Small distance to the next turbine disc on a
rotor will cause no collision trouble due to
size of cutting tool
PATENTED TECHNOLOGY
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„STATE OF THE ART TECHNOLOGY“
BROACHING TECHNOLOGY
Classic technology for serial aerospace
turbine disk manufacturing
Stationary gas turbines or discs can be
manufactured on Multitasking machines
(f.ex. WEINGARTNER mpmc).
IRUBA`s solution can easily be applied to
mill the fir tree slots in all kind of materials
PATENTED TECHNOLOGY
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BASICS OF THE STANDARD TECHNOLOGY
Present technologies carry often
main disadvantages:
1. No save process (full enlacement
/ Insert-/tool breakage)
2. Damage on work piece and/or
spindle
3. Big amount on special tools
4. High cutting forces
5. Long manufacturing time
6. High total cost of production
PATENTED TECHNOLOGY
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RESULTS OF A REAL TEST
PATENTED TECHNOLOGY
WALDRICH COBURG - MULTI TEC
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RESULTS OF A REAL TEST
1.
2.
3.
WALDRICH COBURG - MULTI TEC
Requirements of the
machine:
- Dynamic feed of 2 Axis (X-Y) up
to 2000 mm/min on small diameter
circulation
- Spindle speed in correlation to
diameter of tool max. 5000 Rpm
PATENTED TECHNOLOGY
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RESULTS OF A REAL TEST
WALDRICH COBURG - MULTI TEC
Material (EU)
: 1.2312
Length of Notch
: 150,00 mm
Total Depth of Notch: 98,00 mm
1. Step by Carbide Form End -Mill
ae: ~ 2,0 mm
ap: 36,0 mm
te: ~ 3 min
Q: ~ 85 cm³/min
3. Step by Carbide Form End -Mill
ae: ~ 1,5 mm
ap: 30,0 mm
te: ~ 3 min
Q: ~ 28 c m³/min
PATENTED TECHNOLOGY
2. Step by Carbide Form End -Mill
ae: ~ 1,8 mm
ap: 30,0 mm
te: ~ 3 min
Q: ~ 45 cm³/min
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PROJECT MANAGEMENT
- „GREEN BUTTON“ TECHNOLOGY CONCEPT
- OUTLINE
- TESTS
- SCHEDULING
- IMPLEMENTING
PATENTED TECHNOLOGY
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THE MISSION
PATENTED TECHNOLOGY
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„GREEN BUTTON“ TECHNOLOGY
- Customer will receive:
- Complete new designed serial tool concept
- Complete NC -programming of milling path for each geometry
- Realistic parameters adjusted for tools, machine and material
- Clamping -system with required accuracy and clamping -forces
as well with special cooling concept (water based / oil / ATS/Co2)
PATENTED TECHNOLOGY
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AEROSPACE INDUSTRY
- Realistic tests at DPS (DELCAM UK) workshop
- Original material of INCONEL 718
- Spindle: HSK63A / HSK100A / NEW!: ATS/ CO2 Coolant supply
- Advantage:
No loss of precious machining time at customers tool shop
PATENTED TECHNOLOGY
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STATIONARY GAS INDUSTRY
- Realistic Tests on MC up to Diam. 1300 and/or max. 3,0 to.
- Original Material or similar
- Spindle: HSK100
- Advantage:
No loss of precious Machining time at Customers Tool Shop
PATENTED TECHNOLOGY
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SCHEDULING/ IMPLEMENTING
- DEFINITION OF PROJECT COSTS
- ENGINEERING TO GET MANUFACTURING TIME
AND PRICING OF TOOLS
- CONTRACT
- Example at bottom: Slot length:120mm 2 roughing tools, 1 finish tool,
Total machining time: 4 min/ slot
PATENTED TECHNOLOGY
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SUMMARIZE OF ADVANTAGES
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According to several different test on big and small machines
and due to 5 years of use at the production site at the ABB
(CH).
- Customer will save about 30% machining time, compared to
fastest
available milling technology
- Compared to 800mm disk (Mat. Turbine steel) about same
production time by milling than broaching
- Accuracy and surface quality will improve compared to
broaching
- Dramatic increase of machine flexibility, new invest of
broaching machine can be saved, deburring and probing on
GM: MATTIAS RUTSCHINSKI
PATENTED TECHNOLOGY
M/C available.
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ADVANTAGES of milling by IRUBA vs. broaching
Job description
broaching center
vs.
5 axis miil –turn center
Setup time per disc /serie
0,5- 1h
5 min max. /Pallet
Setup time new serie
6h – 24h
0,5h
Lead time for broach /tool Up to 8 month
Up to 6 weeks
Curved slots
Not possible
limitless
Deburring
Not possible
Both sides in one setup
Probing
2. setup/ no measuring
Same setup
Roughing + finishing
Two setup
One setup
Enviroment
Oil
Water based/ATS/Co 2
PATENTED TECHNOLOGY
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ADVANTAGES of milling by IRUBA vs. broaching
Job description
broaching center
vs.
5 axis miil –turn center
Footprint in workshop
About 150m2
10 – 50m2
Option drilling
Not possible
No limit
Option turning
Not possible
No limit
Power Consumtion
Up to 100KW
45 -56KW / max. 50%
Flexibility
Very limited
Very high
Investment
2 – 20 Mio €
300Tsd – 4Mio €
ROI
3 -5 Years
1,5 Years
Cost per hour
150- 350€
70- 200€
PATENTED TECHNOLOGY
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THINK ABOUT
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HOW TO CONVINCE FOR PRODUCTS MADE FOR „GREEN
TECHNOLOGY “BY USING ALMOST 100 YEAR OLD HEAVY POWER
CONSUMING MACHINETOOL TECHNOLOGY?
PATENTED TECHNOLOGY
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THINK ABOUT
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FACTS:
- IRUBA TECHNOLOGY REDUCES MORE THAN 50% POWER
CONSUMTION BY PRODUCTION SAME WORKPIECE
- LESS MACHINING TIME , LOW LEAD TIME OF TOOLS,
- HIGHEST FEXIBILITY AT THE PRODUCTION SITE
- SMALL „FOOTPRINT“ MACHINES WITH ALMOST DOUBLE
PRODUCTIVITY
- ALL IN ONE -MILLING / TURNING / DRILLING / IRUBA
„BROACHING“ /
DEBURRING / PROBING ON ONE M/C
- NEW: INCONEL FIR TREE MILLING WITH ATS/CO2 COOLANT
PATENTED TECHNOLOGY
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THANK YOU
PATENTED TECHNOLOGY
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