a new green process to machine cfrp safe, clean and ... · a new green process to machine cfrp...
TRANSCRIPT
ASPIRATEA new green process to machine CFRP
safe, clean and efficiently
Dipl.-Ing. MSc. Joseba Pérez BilbatuaInternational R&D Projects Director
5th InternationalCFK-Valley Stade Convention
Overview IDEKO
Basic data: Founded in 1986 IDEKO has approx. 110
employees 85% staff is MSc engineers and
PhD researchers
Source of revenues: 65% business projects 35% public administration
R&D Centre specialized in Manufacturing and Production Technologies
Our mission: “Research for Innovation”!
Manufacturing Processes Machining and material removal
processes Laser materials processing CFRP/GFRP processes CAx, Virtual Reality
Mechanical Design Design of production machines
and components Modelling and Simulation of machines and processes Component and production machines
testing and prototyping
Inspection and Measurement Tactile metrology Optical metrology NDT techniques Laser interferometry Machine-integrated measurement solutions
Manufacturing Management Adaptive and flexible production systems Implementation of LEAN and Six Sigma techniques LCA and LCC applied on machine tools
Strategic Innovation Business development Technology management Innovation management Production management Quality management
Micro and Ultra-precision Development of machines, systems and processes for parts with sub-micrometric tolerances. Fixturing and handling systems
Intelligent Software Adaptive control Control technology and automation Artificial Intelligence systems ICT application on manufacturing Tolerance Management
Dynamics and Control Process modelling and simulations Vibration problems and dynamic design of machine and components Active and passive systems for chatter suppression
Overview IDEKO
CONTENT
ASPIRATE Project
Motivation
Approach and Challenges
Examples
Summary
Critical elements : Hollow tools & Spindle
Critical elements: Vacuum system & Control
ASPIRATE PROJECT
Increase of productivity, safety, greenness and cleanliness in the machining of carbon fibre reinforced composites
ASPIRATE PROJECT
Increase of productivity, safety, greenness and cleanliness in the machining of carbon fibre reinforced composites
Machine toolHollow cutting toolsCoatingsSpindleCutting technologyControl and Vacuum
Technological fields coveredin the project
ASPIRATE Project
Motivation
Approach and Challenges
Examples
Summary
Critical elements : Hollow tools & Spindle
Critical elements: Vacuum system & Control
MOTIVATION
Market Needs Proposed SolutionDesirable Scenario
• CFRP use is increasing in different industrial sectors.
• High range of products, variety
• Clean and efficient CFRP machining processes
• Cost reduction
• Environmental consciousness
• Low health hazards processes
• No geometrical restrictions
• Flexibility in the production
• Clean workpieces
• Clean machine working area / fixturing / peripheral equipment
• Completely safe process
• Collection of chips and dust for disposal
• Cleaning process avoidance
• Internal chip and dust extraction through the tool-toolholder-spindle system
• Completely clean working area and workpieces
• Improved cutting tool life
• No operator hazards
• High flexible process
• Improved finish (no delamination)
• High productivity
MOTIVATION
Traditional approach:External chip/dust extraction
systems
Source: Sandvik
Source: Le Creneau Industriel
Source: CMS Industries
ASPIRATE approach:Internal chip/dust extraction
systems
ASPIRATE Project
Motivation
Approach and Challenges
Examples
Summary
Critical elements : Hollow tools & Spindle
Critical elements: Vacuum system & Control
cutting tip tool shank tool adapter
APPROACH and CHALLENGES
Chip & dust flow
APPROACH and CHALLENGES
APPROACH and CHALLENGES
ASPIRATE Project
Motivation
Approach and Challenges
Critical elements: Vacuum system & Control
Examples
Summary
Critical elements : Hollow tools & Spindle
CRITICAL ELEMENTS : HOLLOW TOOLS
Diamond coated Cemented Carbide tools
PCD teeth brazed steel tube tools
CRITICAL ELEMENTS : SPINDLE
connection with the tool holder
CRITICAL ELEMENTS : SPINDLE
conventional coolant spindle internal chip extraction spindle
5 mmdiameter
10 mmdiameter
CRITICAL ELEMENTS : SPINDLE
connection with the chip extraction system
CRITICAL ELEMENTS : SPINDLE
ASPIRATE Project
Motivation
Approach and Challenges
Critical elements : Hollow tools & Spindle
Critical elements: Vacuum system & Control
Examples
Summary
CRITICAL ELEMENTS : VACUUM SYSTEM
system A system Csystem B
air flow:under-pressure:
240 l/min0.38 bar
air flow:under-pressure:
260 l/min0.72 bar
air flow:under-pressure:
275 l/min0.74 bar
ASPIRATION RATESno
t asp
irate
d ch
ips
0.8
g
0.4
0.2
0.0393
785
chip extraction system
v (m/m
in)
csystem A system B system C
processworkpiecematerial
: groove milling: CFRP
tool geometry tool materialcoatingtool diameter
: ASP_01_7A: hard metal: PCD: Ø 16 mm
cutting speedradial feed rateaxial d.o.c.
: v = 502 m/min: f = 0.3 mm/rev: a= 8 mm
c
p
aspiration system:flowunder pressure
: 275 l/min: 0.74 bar
v
Volume not aspirated always below 1%
CRITICAL ELEMENTS : CONTROL
CRITICAL ELEMENTS : CONTROL
ASPIRATE Project
Motivation
Approach and Challenges
Critical elements : Hollow tools & Spindle
Critical elements: Vacuum system & Control
Examples
Summary
Machining without aspiration Machining with aspiration
SURFACE FINISHING
Excellent finishing (no delamination observed)
SUMMARY
Advantages of the new technology:
Safe and clean working areas
Clean and dry workpieces, do not require further cleaning
Immediate chip/dust processing
Flexible machining / less tools required
Compatible standard with tool-shank (HSK)
Simple: do not require additional devices
