Transcript Výzkumný program obráběcích technologií
R&D of Machining Technologies
assoc. Prof. MSc.
Jan Řehoř, Ph.D.
MSc. Marek Bureš, Ph.D.
23.10.2014
C o n t e n t o f t h e P r e s e n t a t i o n
INTRODUCTION OF RTI Research Programs Departments MACHINING TECHNOLOGY The Main Directions of the R&D The Examples of Collaboration The Future on the Touch 2
Modern vehicles structures and their driving systems
I n t r o d u c t i o n o f R T I
R e s e a r c h P r o g r a m s Production machines and their modernization Forming technologies Machining technologies 3
I n t r o d u c t i o n o f R T I
D e p a r t m e n t s
10 New Laboratories and Testing Rooms:
Laboratory of Experimental Methods for Mech. Engineering Strength and Fatigue Life Testing Room Transport Vehicle Components Testing Room Virtual Prototyping Shop Experimental Forming Laboratory Metallographic Laboratory Mechanical Testing Room Manufacturing Technology Planning Laboratory Experimental Machining Laboratory Metrology Laboratory 4
M a c h i n i n g Te c h n o l o g i e s
T h e M a i n D i r e c t i o n o f t h e R & D I. Machining and diagnosis of complex shape objects – Cutting and Forming Tools, Fixtures, Progressive Technologies, CNC Programming, Metrology and Quality
Short description:
Production of a complex shape products such as molds for die casting and plastic projecting, dies, but also products of the type of crank shafts, blades of steam turbines, turbo impellers etc., bringing them many material, technological and metrological problems. The activity will be defined by a complete solution of the production chain, from research and development of new advanced technological methods of processing (eg HSC, HPC, dry and hard machining, etc.) and non-conventional technologies (Laser, Sonic, Rapid Prototyping, etc.) and their applications through the construction cutting and forming tools, strategy, motion programming tools and on-line production quality management to analyzing and assessing the resulting quality of the machined object (surface integrity). Activities will be coordinated through existing and optimization algorithms developed in parallel to the application, and at the level SW simulation.
Experimental Machining Laboratory Metrology Laboratory 5
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The design of cutting and forming tools
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The geometry and the quality of the cutting edge
Evaluation of the cutting edge wear using a differential analysis 7
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The optimization of cutting conditions using modern advanced machining methods – HSC, HPC, HM, DM, MQL, ....
The experimental milling of sculptured surfaces and turning in HSC regime 8
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects Thanks to the original design of the cutting tool (Milling cutter) using advanced ceramics for HSC milling managed to increase machining productivity in many industrial applications up to 400% !!! Tool with technology was awarded.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects The measuring instrument "HOMMEL ETAMIC T-800" can be advantageously used for profile measurement, in this case it deals the reverse engineering of the component, for which does not already exist drawing documentation.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects An example of point scanning of a precise workpiece for automotive industry by CMM (LK - G90 C) 11
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Contract research
(examples):
New technology for manufacturing of the exhaust protector fixture
Přípravek slouží jako ochrana držáku výfuku při svařování dalších dílů výfuku proti ulpívání odpadních produktů, které by ve výsledku značně poškozovaly silentblok. Selecting the appropriate mix of machining operations led to savings compared to the original technology by 35%. The result will be protected using proven technology in 2014.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Contract research
(examples):
New technology for manufacturing of the molds for pressing catalyst
Jedná se o návrh a ověření celkové technologie obrobení formy pro zalisování dílů pláště výfukového tlumiče. Celkový čas výroby byl zkrácen z 65 hod na 40 hod. Ověřená technologie je registrována zn. 8/TECH/KTO/2013 13
M a c h i n i n g Te c h n o l o g i e s
I. Virtual Technological Preparation of Production
II. Virtual Technological Preparation of Production
• • • •
The ergonomics in repeated manufacturing of small components The ergonomics in the production of the large units Production Layout Simulation and models creation
Manufacturing Technology Planning Laboratory 14 14
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The ergonomics in repeated manufacturing of small components
• • • • • • •
Major benefits
Improvement of the work performance Decrease production of bad products Decrease incapacity and disease from the career Improvement physical and psychical condition of the employees.
Minimization psychical and physical fatigue Improvement of the psychological climate at the workplace The growth company 15
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The ergonomics in the production of the large units
• • • • • •
Using these rationalization measures is possible:
Productivity improvement Planning the steps in the individual operations Simulate the workers activities.
Creating a virtual models of workplace with accurate biomechanical human model Detection load of man at his work with using many ergonomics analyses Feasibility verification of work activities.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The ergonomics in the production of the large units The collision of move
• Impossibility locomotives rotation around its axis – interfere energy distribution • Difficult availibility of worker on the welded places – interfere energy distribution • Problematic of the workers overload Good location Wrong 17
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Production Layout Solutions target and deployment:
• • • • • • • The space saving Manipulation reduction.
Minimization logistics activities Updating and creating the current layout of the production system Today is usually in the interactive 3D view.
The analysis of the production system with regard to the material creation and other material flows.
The calculation of the required number of sites storage in production 18
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Simulation and models creation
• • • • • • The simulation should as first verify intended organizational and the measures control and should eliminate the incorrect decision, which it could lead to the problems in the company. Furthermore is possible: Production increase Position abate (worker, machine) Reduce of worker numbers Risks decrease to go back on terms of contract completion The ensure faster to start-up of new production The ensure faster to start-up of the new transport system.
M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Universal Micro-Tool Grinder Multi-task turning center Rapid prototyping machine - metals Milling machine for machining of very hard non-metallic materials
M a c h i n i n g Te c h n o l o g i e s
Partners
ABF a.s. Praha
– mediální partner, veletrh For Industry AXA CNC stroje s.r.o. Hořovice – výrobce obráběcích strojů
SHM s.r.o. Šumperk
– depozice vrstev na nástroje
GÜHRING s.r.o. Plzeň-Sulkov
– výrobce nástrojů pro obrábění
GTW Bearings s.r.o.
– výrobce kompozicových ložisek ISCAR ČR s.r.o. - distributor nástrojů pro obrábění
SANDVIK CZ s.r.o.
HOFMEISTER s.r.o.
– distributor nástrojů pro obrábění – výrobce nástrojů pro obrábění
PILSEN TOOLS s.r.o.
– výrobce nástrojů a nářadí Saint-Gobain Sekurit ČR s.r.o. Hořovice – Výrobce autoskel
Škoda Power, a.s. Plzeň
– výroba energetických zařízení
SolidVision, s.r.o. Brno
– CAD/CAM/CAE/PDM systémy Strojírna TYC s.r.o. Mýto – výrobce obráběcích strojů SVAZ STROJÍRENSKÉ TECHNOLOGIE – mediální a odborná podpora
ČESKÁ SPOLEČNOST PRO JAKOST, o.s.
– odborná podpora
ČESKÁ SPOLEČNOST STROJÍRENSKÉ TECHNOLOGIE
– mediální a odborná podpora
MM průmyslové spektrum
– vydavatel odborných časopisů Technometra a.s. Praha – výroba součástí pro letecký průmysl
HAM-FINAL s.r.o.
– výrobce nástrojů pro obrábění Pramet Šumperk a.s. – výrobce nástrojů pro obrábění
Asseco Solutions a.s.
– informační systémy
Robert BOSCH, a.s. ČB
– výrobce systémů převážně v segmentu Automotive
ASTRO KOVO Plzeň
– výrobce dílů převážně rotačního charakteru
Innomia , a.s. Jaroměř –
3D tisk plastů a kovů
CompoTech , s.r.o. Sušice
– Výrobce kompozitních materiálů a výrobků