314413Vysoce dynamické frézování tenkostěnných obrobků „DynaMill“
Poskytovatel : Evropská unie
Manažer : Sulitka Matěj
Řešitel : Sulitka Matěj
Výzva : FP7-NMP - Specific Programme "Cooperation": Nanosciences, Materials and new Production Technologies, Nanotechnologies
Příjemce : FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.
Anotace : Lightweight components are gaining in importance in EU key industries with good market growth potential (aerospace, automotive, power generation, medical technology etc.). To achieve weight reductions, complex thin-walled structures are combined with high strength materials. However, the lower stiffness of work pieces leads to severe challenges during the milling process:
- Difficulty to achieve high work piece quality, due to vibration and process forces, in industries that have very high safety and quality requirements (aviation, space etc.). Therefore, in many cases manual finishing of the work pieces is required.
- Achievement of acceptable work piece quality only through time and resource consuming trial and error identification of process parameters that circumvent critical process states. This often results in slow and inefficient processes.
To overcome these problems, DynaMill aims at achieving the complete control over the milling process of thin-walled work pieces. This will be realised through a threefold approach combining the development of process planning, adaptive clamping devices and improved cutting conditions. Subsequently, these three developments will be integrated in the DynaMill Technology as a platform. Throughout the project demonstration of intermediate and integrated solutions will play an important role.
The concrete impacts for industry include:
- 30% reduction of production time and costs
- 80% increase in process stability
- 30% reduction of power, compressed air and coolants
- 60% reduction of process set-up time and 70% reduction of wasted raw materials during set-up
- 20% improvement of tool life
- Elimination of finishing operations
As a result the competiveness of European industry will be enhanced significantly.
For the project, a strong consortium consisting of two research institutes, four manufacturers of key technologies (CAM software, machine tools, clamping devices and tools) and four end users has been gathered.
263385Integrovaný procesní řetězec pro automatizovanou a flexibilní výrobu vláknových termpolastických kompozitů „FibreChain“ Integrovaný procesní řetězec pro automatizovanou a flexibilní výrobu vláknových termoplastických kompozitů „FibreChain“
Poskytovatel : Evropská unie
Manažer : Kolář Petr
Řešitel : Kolář Petr
Výzva : FP7-NMP - Specific Programme "Cooperation": Nanosciences, Materials and new Production Technologies, Nanotechnologies
Příjemce : FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.
Anotace : Lightweight components and their energy-efficient production will form one of the most important key factors for the European industry to fulfil the ever increasing global demands. Nowadays, for 3D-shaped, multi-layered products based on flexible materials only specialized and semi-automated manufacturing equipment is available. The project “Integrated Process Chain for Automated and Flexible Production of Fibre-Reinforced Plastic Products (FibreChain)” aims at the development of worldwide first automated turnkey manufacturing systems for fibre-reinforced thermoplastic composites (FRTC) addressing public and private transportation, mechanical, chemical and civil engineering as well as consumer goods.
FibreChain will generate 20.8 billion € in 5 years and promote a world leading European fibre-reinforced plastics (FRP) industry. FibreChain will more than double the productivity by cost-effective, energy-efficient and flexible manufacturing of FRTCs products due to:
-Customised and yet highly automated production
-Multi-functional (laser) equipment
-Near-Net-Shape production (scrap rates down to 3%)
-Integrated measurement systems
-Knowledge and simulation models along all processes
A multidisciplinary consortium from 7 European countries with outstanding competencies in material, machine tools, manufacturing, laser technology, metrology, simulation and control will accomplish an integrated process chain and make available:
-Process-adapted prepreg materials with carbon, aramid, glass, basalt and natural fibres
-UD-prepregs to overcome drawbacks of fabrics and impregnation processes
-Energy-efficient out-of-autoclave production
-Laser systems and processes for integration of tape laying, cutting and joining
-In-situ integration of holes and inserts during thermoforming
-Integrated material/process data base, simulation and quality assurance system
Thus, OEMs and SMEs synchronise their production of FRTCs with the technological inputs from lean manufacturing systems.
17857Simultaneous five-axis hard milling for highest precision
Poskytovatel : Evropská unie
Manažer : Smolík Jan
Řešitel : Zelený Jaromír
Výzva : FP6-SME - Horizontal research activities involving SMEs: Specific activities covering wider field of research under the Focusing and Integrating Community Research programme 2002-2006.
Příjemce : HEMTECH MACHINE TOOLS BV
Anotace : European tool and die making SMEs are facing a steady loss of competitiveness in their markets, since existing manufacturing technologies cannot fulfil the increasing demands on part quality. These companies are eagerly seeking for new technologies to enhance the economic production of high-quality tools and dies. The main objective of this project is to develop a five-axis hard milling process for highest precision. This new technology will enable end-users to produce high-quality products in less than 62% of current times. This will provide them with a substantial lead over their overseas competitors. The project will encompass the optimisation of a milling machine by applying light-weight parts and the enhancement of milling technology for high-hard materials by process monitoring, as well as of cutting tools and tool coatings for high-performance hard milling operations. Moreover, a part measurement system capable of quality control within the machine tool will be developed. Main work packages are:
-development of a light-weight carbon-fibre spindle box and integration into the milling machine
-development of a novel in machine measurement device
-optimisation of a clamping device
-development of a process monitoring system for small milling tools
-enhancement of cutting tool accuracy and coating technology
-adaptation of CAD/CAM process chain and specialised tool path strategies
-machining technology optimisation
Besides contributing to an improvement of the bonds between Member States and new members, the project will encompass scientific, technical and wider societal objectives:- better scientific and technological knowledge about milling of high-quality surfaces on hardened materials- lifetime enhancement of tools and dies, contributing to further knowledge and productivity of the EU-industry- drastic reduction of hazardous substances in the production of tools and dies significantly improving EU environmental and health conditions.
13989Radikální snížení hmoty a spotřeby energie u nízkoenergetických obráběcích strojů
Poskytovatel : Evropská unie
Manažer : Smolík Jan
Řešitel : Zelený Jaromír
Výzva : FP6-NMP - Nanotechnologies and nanosciences
Příjemce : FUNDACION FATRONIK
Anotace : The ECOFIT proposal addresses as general objective a drastic reduction of the mass of machine tools for production systems (around 70% for structural components and motion units) and, consequently, a reduction of the energy consumption (around 30% less) fo r the use of these new type of machines. ECOFIT represents a radically new approach to industrial machinery conception, aiming at the development of a radically new technology for cleaner and more efficient production, by means of a paradigm shift: changin g from current stiff and massive machinery, with high energy consumption, to lightweight elastic machines with controlled flexibility and thus much lower enrgy needs. This new approach of "lightweight elastic machines with controlled flexibility" represent s an important novelty regarding the way production systems are conceived. It is estimated that currently, approximately an 80% of the total mass of a machine tool is used to stiffen the machine for accuracy purposes, whereas only the remaining 20% is used to fulfil the kinematic requirements of the machine. With the aim of approaching this separation between mechanical stiffness and accuracy in machine tools, this project will combine mass reduction strategies in combination with new control strategies ba sed on damping considerations and new optical servoing solutions. The cornerstone of this new machine conception philosophy is that accuracy will be achieved by mechatronic stiffness against disturbances and external perturbations instead of using mechanic al stiffness to achieve that robustness. This project will reach the frontiers of current knowledge by the synergetic combination of new eco-design methodologies, innovative robust controllers for the flexible mechanism systems, optical servoing and smart materials featuring distributed actuators and sensors to the flexible components. This new approach will be exploited by the proposing industrial companies, builders of machine-tools, of piezo-actuators