desenvolvimentos recentes para uma produção sustentável
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Desenvolvimentos recentes para uma produção sustentável - Recent Developments for a Sustainable ProductionPalestrante: Eng. Markus Röhner - Fraunhofer Institute for Production Systems and Design Technology – FhG IPK / AlemanhaTRANSCRIPT
Desenvolvimentos recentes para uma produção sustentável -
Recent Developments for a Sustainable ProductionDipl.-Ing Markus Röhner
Production Technology Centre Berlin
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I FraunhoferProduction Technology Centre Berlin (PTZ)
I Global TrendsThe Global Markets Beyond Tomorrow
I Brazilian MarketAerospace, Energy, Automotive
I Sustainable ProductionInnovations for your Production Systems
I Services of Fraunhofer IPKExample of Projects
I Fraunhofer IPK in BrazilCooperation Projects
I Contact
Agenda
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FraunhoferProduction Technology Centre Berlin
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The German R&D Innovation Chain
1. Basic research
2. Application-oriented research
3. Industrial application
creates basic innovations.
transfers basic innovations to the application stage and creates prototypical solutions.
implements application-ready solutions in the economy.
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From Idea to Practice : Who stands where?
1. Basic research Universities
Helmholtz Centers Max-Planck-Institutes
2. Application-oriented research Industrial
research centers Fraunhofer Institutes
3. Industrial application Companies
creates basic innovations.
transfers basic innovations to the application stage and creates prototypical solutions.
implements application-ready solutions in the economy.
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The Fraunhofer-Gesellschaft in Germany
60 Institutes more than 20,000 employees
München
Holzkirchen
Freiburg
Efringen-Kirchen
FreisingStuttgart
PfinztalKarlsruheSaarbrücken
St. IngbertKaiserslautern
DarmstadtWürzburg
Erlangen
Nürnberg
Ilmenau
Schkopau
Teltow
Oberhausen
Duisburg
EuskirchenAachenSt. AugustinSchmallenberg
Dortmund
PotsdamBerlin
Rostock
LübeckItzehoe
Braunschweig
Hannover
Bremen
Bremerhaven
Jena
Leipzig
Chemnitz
Dresden
CottbusMagdeburg
Halle
Fürth
Wachtberg
Ettlingen
Kandern
Oldenburg
Freiberg
Paderborn
Kassel
GießenErfurt
Augsburg
Oberpfaffenhofen
Garching
Straubing
Bayreuth
Bronnbach
Prien
Hamburg
Leuna
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Fraunhofer worldwide
Subsidiary Center
Representative Office Senior Advisor
Project Center / Strategic Cooperation7
PTZ Berlin Two Institutes – One Roof
Fraunhofer IPK:Application-oriented research
IWF of the TU Berlin:Fundamental research
PTZ Berlin Two Institutes – One Roof
Automation
Technology
Virtual Product
Creation
Corporate Management
Production Systems
Medical Technology
Assembly Technology and
Factory Management
Industrial Automation
Technology
Machine Tools and
Manufacturing Technology
Industrial Information
Technology
Quality Science
Joining and Coating
Technology
Quality Management
Joining and Coating
Technology
PTZ Berlin Two Institutes – For The Entire Manufacturing Process Chain
Managing
companies
Developing products
…with innovative
manufacturing technologies,
…and automated
methods
Guaranteeing quality
Manufacturing products…
Automation
Technology
Virtual Product
Creation
Corporate
Management
Production Systems
Assembly Technology and
Factory Management
Industrial Automation
Technology
Machine Tools and Manu-
facturing Technology
Industrial Information
Technology
Quality Science
Joining and Coating
Technology
Joining and Coating
Technology
Quality Management
…machines and
tools,
Global Trends & Brazilian MarketThe Global Markets Beyond Tomorrow
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Global Trends
Verkürzung und
Dynamisierung der
Produktlebens-zyklen
Globalisierung
Individualität der Märkte
Klimawandel und
Ressourcen-verknappung
LernendeGesellschaft/
Wissens-gesellschaft
DemografischerWandel
Durchdringung mit neuen Technologien
Mobilität
Production and
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Global Trends
Production and
Shortening and
dynamic of the product life cycles
Global Markets
Individuality of the
markets
Climate change and
resource scarcity
Learning Society /
Knowledge Society
Demographic
change
New technology
Mobility
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Brazilian MarketAerospace, Energy, Automotive
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Important sectors of the Brazilian Industry
Oil & Gas Sector, Raw materials
Renewable and Clean Energy
Automotive
Aerospace
© Toyota
© Brasil Maior
© Brasil Maior
© Embraer
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Brazilian Industry Needs
Development of turbo machines
Development of micro and small gas turbines for decentralized CHP plants using renewable energy sources (biomass, waste process)
Efficient tools, kinematics and machining technologies ceramic tools, rope kinematic
Hybrid process robot based systems for milling, positioning of parts, pre treatments
Services, monitoring systems, maintenance concepts
Downsizing, Lightweight Design, emission reduction (CO2), new materials (Flex motor)
© Toyota
© Brasil Maior
© Brasil Maior
© Embraer
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Sustainable ProductionInnovations for your Production Systems
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Sustainability in Production
Future strategies, dimensions of sustainability,major developments
Key technologies for production systems and manufacturing processes
Content
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Sustainability in Production
Future strategies, dimensions of sustainability,major developments
Key technologies for production systems and manufacturing processes
Content
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»Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs.« (Brundtland Report, Work Commission on Environment and Development: Our Common Future, Oxford, 1987.)
»Sustainability is the concept of a permanent, future proof development of the economic, ecological and social dimension of human existence. These three pillars of sustainability are interdependent and require a long-term balanced coordination.« (Final report of the Enquete Commission of the 13th German Bundestag, printed paper 13/11200, Berlin, 1998.)
The Term »Sustainable Development«
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Sustainability in Production
•Employee satisfaction
•Health
•Minimum social standards
•Safety
•Education
•Human-centered production
Economic Ecological Social
•Life cycle extension of resources
(reuse, low-wear components, modular concepts, availability management)
•Renewable and recycled materials
•Regenerative use of energy
•Resource productivity (materials, energy, supplies, operating resources)
•Technology competence
•Minimizing production costs (fast flawless production,0-failure production process chain reduction, process substitution)
•Versatile production
•Efficient employee assignment
Dimensions of Sustainability
Sustainability in production
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Market growth
Innovation degree
Product & Process
Existing markets New markets
New
Products & processes
Existing
Products & processes
Sustainability in productionStrategies for guaranteeing the future of production
Customer adapted technologies with regard to costs, quality & time
Local business networks
Surviving strategies
Customer/ culture adapted technologies
Global business networks
Expansion strategies
Intelligent technologies
Market leadership
Safety strategies
Novel technologies
Technology leadership
Pioneer strategies
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1900 1950 2000
number of employeesresource
manufacturing timewaste
costs emissionsenergy
time ofproduct development
need of knowledgecustomer proximity
variety of productsproduction safety variety of methods
competitionservice
material variety
localized regionalized internationalized relocalizedglobalized
productivity costs quality environment mutabilityCharacteristic
factorytemporary
business alliances
Combine with
subsidiary company
Production
mass product variety product individual productProduct
customerorientation
Strategy productionorientation
marketingorientation
sustainabilityorientation
hybrid product
business
network
flexibilty
intagratibility
2050
The way to sustainability orientation
Sustainability in production
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Sustainability in Production
Future strategies, dimensions of sustainability,major developments
Key technologies for production systems and manufacturing processes
Content
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Tools Machines andcomponents
Materials
Manufacturingtechnologies
Process chains
Materials
- Ultra hard materials (ni, ti based)
- Lightweight materials (Mg, Al-alloys, metal foams)
- Composite materials (FRP, CFRP, MMC, reinforced ceramic)
- Sintered materials (metallic, ceramic)
Tools
- Coating technologies
- Innovative cutting tools
- Micro tools
- Holistic view on design, production and inset
Manufacturing technologies
- High speed machining- High performance machining
- Hard machining- Ultra precision and micro machining
- Hybrid technologies- Dry machining- Rapid Prototyping
- und Rapid Tooling
Process chains
Reducing process chains by:- Process substitution-Near-Net-Shape technologies
-Highly integrated production
- Integrated production and process development
Key technologies for a sustainable production
Machines and-components
- Innovative machine components
- Self-optimizing, adaptronic structures
- Magnetofluidicpositioning systems
- Strut and rope kinematics
- Reconfigurable machines
Innovation fields of production technology
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Hybrid processing
Geometry identification
Measuring point
Laser abrasion
100 μm
Micro milling
100 μm
Manufacture of parts
Die-set
High precision-machine tool for combined milling/laser processing
measuring
(geometry)
Spindle II
(milling)
Spindle I
(milling)
scanner, lenses
(laser abrasion)
Combination of micro miller and laser abrasion form construction
Milling processing hardened tool steel with ultra micro grain-Hard metal tools up to nominal diameter 0.2 mm
Nearly meltfree laser abrasion using pulsed laser radiation (puls duration < 15 ps, average power 800 mW)
laser processing of pre-milled structured for shortening process times in comparison to complete processing via laser
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Tensile Strength [MPa] 0,2 % Proof Stress [MPa] Breaking Elongation [%]
IN 718, conventional, T = 20°C [1] 1276 1034 6 - 12IN 718, conventional, T = 650°C [1] 1000 862 6 - 12IN 718, melted, T = 20°C [2] 1295 1110 10 - 13IN 718, melted, T = 650°C [2] 1065 905 10 - 13
Selective Laser Melting – Form-flexible production of turbine blades Advantages
Flexible, additive manufacturing process
Manufacturing and repair of compressor and turbine blades of TiAl6V4,
TiAl6Nb7, INC 718, Hastelloy X , Renè 80 using laser radiation
Potentials in design and functionality by assembling parts layer by layer
Strength of generated structures corresponds to those of cast parts
Reduction of inner density of parts by 90 % and of inertia of rotating
components by 30 % using a lattice structure for high part stiffness
Topics
Processing turbine materials with selective laser melting e.g. René 80
Tailor made adjustment of workpiece properties e.g. density, strengthGenerated blade
[2] Inno-Shape: Laserschmelzen von Nickelbasiswerkstoffen; Aachen, Firmenschrift[1] Special Metalls: INCONEL ® alloy 718, Huntington US, 2007, Firmenschrift
Exposure of partgeometrie
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10 μm
vc = 30 m/min
10 μm
vc = 300 m/min
HSC of Titan-Aluminides
Motivation
Outstanding material properties: low density,
high tensile strenght, high oxidation and
corrosion resistance
Conventional machining induce the
generation of cracks at the workpiece surface
HSC
-Ma
chin
ing
Co
nven
tio
nal M
ach
inin
g o
f TiA
l
Conventional machined TiAl HSC-machined TiAl
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HPC-Machining with ceramic cutting
tools. Source: IPK
Conventional machining of
a Ni-based superalloy. Source: IPK
Performance of ceramic cutting tools
Increase of cutting velocity by factor 50
Increase of the material removal rate by factor 40
Significant reduction of the machining time
Significant reduction in the manufacturing costs
s
Milling of IN718
0
125
250
500
Mach
inin
gT
ime t
h
conventional
(vc = 35 m/min)
HPC
(vc = 600 m/min)
Cutting Speed
High Performance Milling of Ni-Superalloys with ceramic cutting tools
HPC with Indexable Inserts
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Motivation
Transfer potentials of ceramic cutting tools to applications
with tool diameters smaller 16 mm.
Goals
Establishment of a knowledge base for design and use of
monolithic ceramic cutting tools.
Development of prototype tools as innovation impulse for
tool producers and turbine production.
Background
Substantial knowledge in tool design, use of ceramic cutting
tools and their application in industrial environments
Excellent equipment for development, manufacturing and
test of tool under one roof in Production Technology Center
Berlin (PTZ)
Face milling tool made of SiAlON-ceramicSource: IPK
High Performance Milling of Ni-Superalloys with ceramic cutting tools
Development of ceramic milling cutters
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First prototype tool with diameter of 25 mm (CerCut) , Source: IPK
Milling cutter with diameter of 4 mm made of whisker-ceramic (TechVolk)Source: IPK
High Performance Milling of Ni-Superalloys with ceramic cutting tools
AdvanCer „CerCut“
Fraunhofer internal research project
Manufacturing and test of first prototypes
Identification and syndication of industrial partners
InnoNet „TechVolk“
Public and industrial funded research project:
four research institutes and eight companies
Development of complete process chain:
manufacturing of raw material, grinding of tools,
application with modern machine tools
Industrial Implementation concept
Bilateral projects with gas turbine manufacturers
Machining concept for guide vanes:
strategies und parameters, clamping, machine tool.
Projects and Experiences since 2005
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High Performance Milling of Ni-Superalloys with ceramic cutting tools
Industrial Implementation concept
Allowances Accessibility
Part Geometry
Path Planning
Tool Geometries
Spindle Technology
KinematicsClamping and Set-ups
Drives and Dynamics
Machining Strategy Machine Tool Technology
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Comparative investigations with cemented carbide tools
Groove-milling in MAR M247 with full cut and cutting
material adapted parameters
Increase of cutting speed by factor 40
Increase of material removal rate by factor 8
Mat
eria
l Rem
ova
l Rat
e Q
W
1.000
1.500
mm³/min
2.500
500
0
CC Sialon
4
Cutting Material
D [mm]
4z [1]
4ae [mm]
1ap [mm] 0.2
10vc [m/min] 400
0.02fz [mm]
255Qw [mm3 /min] 2.037
MAR M247Material
EmulsionLubricant dry
cutters for comparative investigations:a) cemented carbide; b) Sialon Source: IPK
High Performance Milling of Ni-Superalloys with ceramic cutting tools
Benchmark of Cemented Carbide and SiAlON
a) b)
High speed machining with ceramic milling cutters. Source: IPK
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Objectives and Work Packages
Development of a quality management
system for the qualification of tool electrode
suppliers
Optimization of the EDM-machining process
for producing seal slots – reduction of
process time and electrode wear
Guarantee the requirements for machining
results (roughness, cracks, form accuracy and
thermal influenced layer)
Modification of machine-tool for producing
seal slots by application of piezo-actuators
GP 7000 for Airbus A380(Quelle: MTU Aero Engines)
Fabrication of Seal Slots in Turbine Components
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GP 7000 for Airbus A380(Source: MTU Aero Engines)
Fabrication of Seal Slots in Turbine Components
Results
Development of two distinct technologies:
maximum increase of the material removal
rate about 173%
maximum reduction of the machining time
about 54%
maximum reduction of tool electrode wear
about 30%
Implementation of the multi step-technology
All quality requirements to the produced seal
slots have been reached
Implementation and validation of results at the
project partner’s machine tool
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Combined Laser-EDM Machining Center (IPK-ILT)
Manufacturing of cooling holes
Motivation
Development of a flexible hybrid Laser-EDM machining
center for producing boreholes with complex forms
Application
Cooling holes in turbo machinery ,
Injection nozzles in automotive
Results
Reduction of process time about 50 %
Development of a vibration unit through piezoelectric
actuators aiming the improvement of the flushing
conditions
Boreholes Laser (left), Laser+ EDM (right)
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Abrasive Flow Machining
Finishing of complex geometries by
machining with abrasive suspension
cylinder abrasive medium piston
workpieceworkpiece holder
cylinder piston
Applications
Machining of hard materials with SiC or diamond grains
Deburring, edge rounding and polishing
Optimization of surface quality (up to Ra = 0.1 μm)
Improvement of air flow conditions
Process simulation by Discrete Element Method
Turbine Blade and work piece holder for machining with AFMBefore AFM After AFM
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Services of Fraunhofer IPKExample of Projects: factory planning, process chain and technology developments
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Initial situation: 4 manufacturing sites
TAG: gas, steam, water turbines
LMZ: gas, steam, water turbines
Elektrosila: generators
ZTL: blades
Goal:
Green field planning for the production of
gas, steam and water turbines
Optimization concept for TAG and
blades manufacturing site
Power Machines, St. Petersburg, RussiaFactory Planning
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Validation of the
developed rough layout
Layout and capacity
planning
Determination and
optimization of the
material flow
3D – Visualization of the
layout
Evaluation and
improvement of the
ramp-up plan
Siemens Gas Turbine Parts Ltd., Shanghai, Optimization of the manufacturing concept
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„INLINE“ Siemens Gas Turbine Plant, Berlin, Planning of the Blades Manufacturing
Development and Implementation
of manufacturing, organization, IT
and technology concepts
Reduction of the manufacturing
costs by 15%, throughput time
by 40 %
Company-wide implementation of
the technology Roadmap
(Lead factory Berlin)
R&D Partnership
initiation
Figure: Gas Turbine Blade
2nd place in Siemens „Team Award“category
„3i Manufacturing Excellence„ (500 submitted projects)
Analysis and Assessment
Developing Proposals for Implementation
Identification of
Key Innovations
Factory planning Manufacturing Technology
Developing
Rough Concept
Ensuring
Potentials
Specification and
Validation
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Introduction into Technology Road Mapping Approach of IPK
Proceeding in technology road mapping
Detection of relevant technologies
Analysis of technological environment, company and competitors Targets, time horizon and level of detail
Demand analysis and prognosis
Analysis of technology complexes
Potential analysis and prognosis
Scenario analysis
Generation of the road map
Detailed performance requirements Relations of dependencies Date of realization Sufficiency and economy analysis
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mroin Energie und Verkehr
mroin Energie und Verkehr
© Fraunhofer
Maintenance, Repair and Overhaul Goods with high investment costs and long product lifecycles Revenues from after-sales (MRO) contracts account for a substantial portion of
the overall profit Low level of scientific background, high research demand on MRO techniques High technological and economical potential
Sectors
Railway
Road AviationAero-engines
Wind energy
Stationary Turbines
Solar energy
Transport Energy
Transfer of the technical expertises to other sectors
MRO in Energy and Transport
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mroin Energie und Verkehr
mroin Energie und Verkehr
© Fraunhofer
Partner des Innovationsclusters MRO
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mroin Energie und Verkehr
mroin Energie und Verkehr
© Fraunhofer
Structure and organisation
Goals of the Innovation Cluster: Formation of an internationally renowned, highly component MRO-region in Berlin and
Brandenburg Know-how transfer between the transportation, energy and other sectors Conservation of resources due to the extended service life time enabled by the
deployment of enhanced MRO-strategies and technologies
Funding: industry: 4.200.000 € Berlin and Brandenburg: 6.800.000 € Fraunhofer-Gesellschaft: 4.600.000 €
Research and development on MRO-Topics by the Fraunhofer innovation clusterMRO in 3 years is funded with 15 600 000 €
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mroin Energie und Verkehr
mroin Energie und Verkehr
© Fraunhofer
Project Forms in the Innovation Cluster MRO
Innovation Cluster are project cluster Financing of projects
Industrial project : Research by order:
Subject defined by and project paid by industrial partners, confidentiality
Transfer project: Definition of contents and work plan by
R&D-partners and industry, mixed funding with different public portion
Initial research: Interdisciplinary subjects, definition by R&D-
partner based on recommendation by industry, public funding, publication of results
Interdisciplinarity
Transfer projects
IndustrialProjects
Initial research
Direct applicability
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mroin Energie und Verkehr
mroin Energie und Verkehr
© Fraunhofer
Fields of innovation
MRO-Planning and digital assistance
Industrial cleaningCondition monitoring and diagnostics
Repair technologies
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Main costs
Assembling and disassembling
Costs of repair of single parts
Material costs of replaced components
Example moving blade
OEMs allow only one single complete
overhaul
Afterwards replacement of new parts
New part costs approx. 500.000 $ for one set
of 1st HDT rotor stage
Direct operation costs of airlines
Distribution of engine costs
Ru
pp
, MTU
Mai
nte
nan
ce H
ann
ove
r
20 % of the total costs of an airline are MRO-costs. 8 % of operation costs are for the MRO of engines.
Relevance of MRO for Airlines
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Robot based automation of maintenance operations and finishing of turbine blades
DecoatingCleaning
IndicationParameterization
Repair welding
Milling GrindingPolishing
HardeningCutting
Repair process chain
Challenge
Varying conditions of parts and fast response times for lot size 1
Low process safety of particular repair steps due to manual operation
Approach
Providing a complete solution for the entire repair process chain
including technologies
Robot operated processing with functionality of machine tools and
iterative processing up to requested precision
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Initial situation
Disks operate at loads up to 100t at temperatures up to 1000°C.
Cracks of 1/10 mm lead to catastrophic failures of the parts.
Edges of the parts are highly critical geometric elements with strict
constraints regarding form and surface integrity.
Actually mainly manual manufacturing with high qualified staff.
Automated edge preparation will increase due to demands from OEMs.
Milling and brushing using CNC machine tools needs high preparation
efforts and is cost intensive due to high machine costs
Manuel edge preparation
Processing of edges on rotor parts of aero turbines
MTU BLISK (Source MTU)
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Challenges
Find a economic and automated solution to fulfill the requirements
Flexible processes to manufacture different parts
Ability for offline programming
Manufacturing of complete batches without input of worker
Approach
Combination of milling and brushing with pliant tools
Process development for representative features of the turbine parts
Robot based process offers high flexibility at low investment costs
Processing of edges on rotor parts of aero turbines
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Achievements
Realization of a forced controlled machining to achieve high accuracies
Planning of robot configurations under consideration of accessibility,
movement capabilities and stiffness of the robot system and local adaption
of iterative machining plan
Development of milling and grinding technologies for different machining
tasks
Compensation of tool wear in milling operations
Test and implementation of developed processes and technologies at our
customers
Application
Finishing of blades and complex parts using belt grinding and vibratory
finishing
Deburring and chamfering of complex parts
Robot operated milling and grinding for finishing of complex parts
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Fraunhofer IPK in BrazilCooperation Projects
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Fraunhofer IPK in Brazil
Actual Projects from Fraunhofer IPK in Brazil :
Turbine Producer: GMA (Gas Metal Arc) Narrow Gap Welding of Hydro Turbine Casings
PUC Rio/ MCTI: Prototypical Implementation of Intellectual Capital Statements in SME
SENAI: Planning and Development of the National Management of SENAI's Institutes as well as existing and future Innovation Institutes
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Desenvolvimentos recentes para uma produção sustentável -
Recent Developments for a Sustainable Production
Thank youfor
your attention!
Production Technology Centre Berlin
Markus Roehner
Head of Manufacturing Technologies
Fraunhofer Institute
Production Systems and Design Technology IPK
Pascalstrasse 8-9
10587 Berlin
Phone +49 (0)30 / 3 90 06-279
Email [email protected]
Internet www.ipk.fraunhofer.de
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