Se buscan empresas Desarrolladoras/Fabricantes de Utillaje y de Maquinaria de corte interesadas en participar en Proyecto Europeo: “Development of simultaneous three axis turning”
INFORMACIÓN SOBRE LA PROPUESTA Y SOCIO BUSCADO
Development of simultaneous three axis turning
The project is focused on the development of a novel three axis turning technology for manufacturing of complex rotationally symmetric parts made of highly strengthened materials. The project objective is to overcome disadvantages of current two axis turning technologies such as large tool wear, frequent tool changes and low efficiency. Within the project lathes will be equipped with a third axis, computer aided manufacturing (CAM) software will be developed and suitable tool holders and insert-geometries will be chosen. Thus, cost and time in turning operations of either complex geometrical parts or hard to machine materials will be significantly reduced.
The benefits of simultaneous three axis turning are the following: reduced amount of tool holders, increased tool life (insert), reduced non-productive times due to tool and tool-holder changes, reduced costs in production through increased efficiency and reduced waste.
The turning of complex parts made of difficult to machine materials is time and cost intensive. One reason for this is the large tool wear which leads to frequent tool changes and therefore to increased non-productive times. On the other hand the geometrical limitations in state of the art turning make a frequent tool holder change necessary when complex geometries are machined. Within this project lathes will be equipped with a third axis, computer aided manufacturing (CAM) software will be developed and suitable tool holders and insert-geometries will be chosen. Thus, cost and time in turning operations of either complex geometrical parts or hard to machine materials will be significantly reduced.
In most of the turn-/mill centres a third axis (b-axis) is already available, but only used for milling operations. Turning operations are still performed by two axes, even if the third b-axis is already present. The reason for this is that simultaneous three axis turning is a yet unexplored technology: on the one hand no suitable computer aided manufacturing (CAM) systems are available on the market which support the integration of the b-axis in the turning process. On the other hand no experience and knowledge exist in regards to tool path planning, tool geometries and tool wear. Thereby, a great benefit could be generated by the use of the b-axis in turning: reduced amount of tool holders, increased tool life (insert), reduced non-productive times due to tool and tool-holder changes, reduced costs in production through increased efficiency and reduced waste. Simultaneous three axis turning is yet an unexplored technology. Due to missing suitable CAM-systems and missing process knowledge, simultaneous three axis turning is widely unknown in industry, even if high potential benefits are on hand. To make knowledge, simultaneous three axis turning applicable for industry, especially for SMEs, it is the goal within this project to provide a technology platform which allows the end-user the full advantage- and easy-use of knowledge, simultaneous three axis turning. To achieve this, the project is structured into three modules and a subsequent verification:
Module 1: Process planning
As already mentioned, no CAM-systems support three axis turning yet. Therefore it is required in a first step to develop a CAM-module which enables the reliable and collision-free planning of the tool paths in three axis turning. In a second step the results and developments, which are gained in the other modules will be integrated into the CAM-module afterwards. At the end of the project a CAM module should be available, which works with all major CAM-systems and brings already during the process planning phase the full benefit of knowledge, simultaneous three axis turning to the end-user.
Module 2: Tooling
The entire market of turning tools is optimized for two axis turning processes. Due to the use of a third axis, geometric tool limitations can be eliminated. This enables the application of new tool designs. Tool geometries which combine multiple single geometry elements in one tool (e.g. round and cornered) are applicable due to this. By using the b-axis the different geometries can be used in dependence of the individual machining case. Such novel tools & tool holder, which are tailored for three axis turning, need to be developed within this module and to be integrated in the CAM-module.
Due to the customization of the tools, common online tool measurement systems which are usually integrated within the lathes, are not sufficient for recognition of complex tool shapes. It is necessary to develop a system which can measure the exact geometry of freeform tool geometries reliable and deliver this data to the machine controls. At the end of the project a tool measurement system and tailored tools should be available which bring the full benefit of three axis turning to the end user.
Module 3: Machining strategies
Three axis turning is yet an unexplored technology. It is unknown which effect the variation of the contact condition has by means of forces, surface roughness and tool wear. These will be investigated within this module, by the development of an analytic machining model. Furthermore, analogy experiments and turning experiments will be conducted to verify the model. The results of module 3 will be integrated into the CAM-module. At the end of the project an universal process systematic will be available, which can be used for the design of machining strategies in simultaneous three axis turning. Hereby the goal is to achieve the optimum machining strategy regarding material removal rate, manufacturing time, surface quality and tool wear.
To verify the developed simultaneous three axis turning technology, case studies will be performed. Hereby the benefit of simultaneous three axis turning will be quantified by comparison of former manufacturing processes and the newly developed simultaneous three axis turning process. At the end of the project it will be shown, that simultaneous three axis turning leads to a significant larger tool life, a remarkably larger process flexibility and a decreased amount of tool holders. Thus, cost and manufacturing time are reduced significantly.
PARTNER PROFILE SOUGHT
Already existing consortium:
The coordinator is a German R&D performer specialized in production technology (process technology, production machines, mechatronics, production metrology).
Partners sought and role in the project:
The coordinator looks for the following SME partners:
- A CAM-software manufacturer who is able to develop a CAM-module that can do the flexible, reliable and collision-free tool path planning in three axis turning. The CAM-module has to work with all major CAM-Systems for maximal dissemination of the technology.
- A tool and tool holder manufacturer who has expertise in the development of customized tools made of different materials.
- A manufacturer of tool measurement systems who has expertise in the development of such systems.
- End users who are interested in the verification and application of the simultaneous three axis turning technology.
INFORMACIÓN SOBRE LA CONVOCATORIA
· Call Identifier: FP7-SME-2013
· Activity Area: Research for the benefit of SMEs
· Funding Schemes: Research for the benefit of specific groups (SMEs)
· Evaluation Scheme: Complete Proposal
· Closure Date: 15/11/2012
Mª Dolores Guillén
Tel.+34 955 00 74 78