Intefix_webinar

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Information about Intefix_webinar

Published on March 21, 2014

Author: I4MS_eu

Source: slideshare.net

Description

Intefix Open Call Webinar. INTEFIX aims to increase the performance of the machining processes by the use of intelligent fixture systems, allowing the monitoring, control and adaptation of the process to obtain suitable results according to precision, quality and cost requirements.

INTElligent FIXtures for the manufacturing of low rigidity components Grant agreement no: 609306 WEBINAR: INTEFIX OPENCALL Oscar Gonzalo 21/03/2014 This project is part of the I4MS initiative

CONTENTS • INFORMATION ABOUT THE PROJECT • Objectives • General structure • Management • Opencall• Opencall • DESCRIPTION OF CURRENT CASE STUDIES • REMARKS FOR THE OPENCALL APPLICANTS

Partners: 22 Starting date: July 2013 Ending date: June 2016 Duration: 3 years/36 month Budget: 9.639.391 € PROJECT DATA EC contribution: 7.499.998 € (including the OPENCALL) OPENCALL: EC contribution: 1.450.000 € Call closure date: April 2nd 2014 Minimum number of new experiments: 3

INTRODUCTION Manufacturing: machining processes Machine Fixture Process FIXTURE: • Securely HOLD and accurately LOCATE the workpiece • Affects PRECISION, QUALITY and COST

INTEFIX APPROACH CONCEPTS: INTELLIGENT FIXTURES Monitoring (sensors) Control Adaption (actuators) Precision Quality Cost CONCEPTS: • Mechatronic/Adaptronic systems • Adaptability (Tunable behaviour) • Modularity (Modular elements) • Flexibility (Other applications: welding, assembly...)

INTEFIX APPROACH VIBRATION POSITIONINGPOSITIONING DEFORMATION

MAIN OBJECTIVE The INTEFIX project aims to establish fixture design methodologies taking advantage of the available state of the art software and hardware tools (sensors, actuators, CAD/CAM/CAE, CNC, PLC, process simulation tools,...) combined with ad-hoc ICT tools (control algorithms, simulation tools...) to control and adapt the behaviour of the fixture, resulting in the development of intelligent fixtures. These methodologies will be based on the use of modular elements to obtain highly configurable, fast, accurate and durable fixture systems. Experiments ⇒ MethodologyExperiments ⇒ Methodology State of the art systems ⇒ Integration Modular elements ⇒ Configurability & Reusability Adaptive fixture ⇒ Intelligent fixtures – Fast and accurate

PROJECT STRUCTURE • SCENARIO 1: VIBRATION [2] • SCENARIO 2: DEFORMATION [4] • SCENARIO 3: POSITIONING [2] CASE STUDY n EXPERIMENTS (18 months) Selected case studies/aplications SENSORS ACTUATORS SOFTWAREAND ALGORITHMS MONITORING ANDCONTROL FIXTURES MACHINING TECHNOLOGIES CASE STUDY n Coordinatingpartner Technology supplyers End-user RTD performers SENSORS ACTUATORS SOFTWAREAND ALGORITHMS MONITORING AND FIXTURES MACHINING TECHNOLOGIES ALAVA C-TEC INVENT AI MATZAT AI COMPOTECH STERN C-TEC BCT IDEKO TEKNIKER TUDo RCMT OvGU/IFQ IDEKO TEKNIKER RCMT AI MATZAT ROEMHELD GIGGEL AI COMPOTECH INVENT SORALUCE ITP DEHARDE SORALUCE GOIMEK GIGGEL TYC KALEAERO

MANAGEMENT Committees at different levels • Steering • Exploitation, IPR & dissemination • Technical TECHNICAL COMMITTEE OvGU/IFQ-RCMT- STEERINGCOMMITTEE Membersto be appointedat Kick-Off EXPLOITATION, IPR and DISSEMINATION COMMITTEE Chairman:CECIMO COORDINATOR EU WP Leaders• Technical • General assembly GENERAL ASSEMBLY (The whole consortium) NEW case studies through Open Calls Scenario1: Vibration Case Study 1 Case Study 2 Scenario 2: Deformation Case Study 1 Case Study 2 Case Study 3 Case Study 4 Scenario3: Positioning Case Study 1 Case Study 2 TECHNICAL COMMITTEE OvGU/IFQ-RCMT- IDEKO Dissemination: CECIMO Exploitation IPR: C-TEC WP Leaders Other participants

OPENCALL Definition of the problem (Vibration/Distortion/ Positioning) Form a miniconsortium Submission of the proposal Incorporation of new experiments to the project Deadline for proposals submission: April 2, 2014 Evaluation results of the Opencall: May 29, 2014. Start of the new experiments: July 1, 2014 Maximum EU contribution: up to 485.000 €/proposal

PROJECT PLANNING Technical WPs from OPENCALL ID WORK PACKAGE / TASK T 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 WP 13 Case study 0.1. Open call for the Scenario 1: Vibration 18 T 13.1 General analysis and definition of the fixture configuration 9 T 13.2 Development of the fixture control 9 T 13.3 Detailed design. Manufacturing and assembly of the test platform 6 T 13.4 Test. Verification and validation 3 WP 14 Case study 0.2. Open call for the Scenario 2: Deformation 18 T 14.1 General analysis and definition of the fixture configuration 9 T 14.2 Development of the fixture control 9 T 14.3 Detailed design. Manufacturing and assembly of the test platform 6 T 14.4 Test. Verification and validation 3 Year 1 Year 2 Year 3 T 14.4 Test. Verification and validation 3 WP 15 Case study 0.3. Open call for the Scenario 3: Positioning 18 T 13.1 General analysis and definition of the fixture configuration 9 T 15.2 Development of the fixture control 9 T 15.3 Detailed design. Manufacturing and assembly of the test platform 6 T 15.4 Test. Verification and validation 3

PROJECT PLANNING GENERAL WPs ID WORK PACKAGE / TASK T 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 WP 1 Project Management 36 T 1.1 Establish INTEFIX administration and methodologies for integrating project activities 3 T 1.2 Management and Coordination 36 T 1.3 Administration and Support activities 36 T 1.4 Open Call. Mechanism implementation 36 WP 2 Training, dissemination and exploitation 36 T 2.1 Training activities 36 T 2.2 Dissemination strategy and activities 36 T 2.3 Exploitation activities 36 T 2.4 Standardization activities 36 Year 1 Year 2 Year 3 T 2.4 Standardization activities 36 WP 3 Specifications 6 T 3.1 General specifications 6 T 3.2 Specifications of experiments in Scenario 1: Vibrations 6 T 3.3 Specifications of experiments in Scenario 2: Deformations 6 T 3.4 Specifications of experiments in Scenario 3: Positioning 6 T 3.5 Definition of the required specifications for the OPEN CALL case studies 6 WP 4 INTEFIX methodology development 12 T 4.1 Methodology for cases in Scenario 1: Vibrations 12 T 4.2 Methodology for cases in Scenario 2: Deformations 12 T 4.3 Methodology for cases in Scenario 3: Positioning 12

SCENARIO 1: VIBRATION CS 1.1 Identification and active damping of critical workpiece vibrations in milling of thin-walled impellers/blisks. Description: • Impeller made of EN AW-7075 aluminium by 5-axis milling. • Reduce the vibrations in the machining of the blades. • Integration of sensors and actuators for monitoring the process and for avoiding unstable conditions (chatter). • Vibrations occurs due to low stiffness and cutting forces, resulting in unstable cutting, bad surface finishing and tool wear.wear. Partners: • GIGGEL GmbH; ROEMHELD GmbH; INVENT GmbH; CEDRAT Technologies; ISF (TUDortmund); IFQ (OvGU- Magdeburg) Description of the solution: • Development of an “i-chuck”: new chuck with integrated sensors able to detect the unstable cutting, also including actuators to counteract the vibrations • Use of dynamic simulations of the cutting process as an input

Turning of low pressure turbine casing. Description: • Low pressure turbine case made of INCONEL 718. Dimensions: D=1800 mm; H=550 mm; e=2.5-6 mm. • The process performance is limited by the vibrations, i.e. low cutting conditions and reduced tool life • Vibrations result in bad surface finish and integrity ⇒ Potential component rejection (Scrap) • Variable dynamic behaviour due to the material removal process • Rotating workpiece in the vertical lathe SCENARIO 1: VIBRATION CS 1.2 Partners: • ITP; INVENT GmbH; CEDRAT TECHNOLOGIES; COMPOTECH s.r.o.; ALAVA Ingenieros; ADAPTRONICS International GmbH; IK4-TEKNIKER Description of the solution: • Integration of sensors and actuators • Capability to detect the vibrations • Modification of the system behaviour: machine-fixture-workpiece • Modify the boundary conditions of the workpiece to change the dynamic behaviour: force, pressure, damping ⇒ Modification of the stiffness and damping, adjusting of the position and clamping force

SCENARIO 2: DEFORMATION CS 2.1 Detection and compensation of workpiece distortions during machining of slender and thin-walled aerospace parts. Description: • Estructural component made of aluminium for the aerospace sector • Distortions occur due to the residual stresses and the high amount of material removed from the raw workpiece • Out of tolerances workpieces • Integrate systems to detect the distortions and compesate the deviations using actuators Partners: • DEHARDE; GIGGEL GmbH; ROEMHELD GmbH; INVENT GmbH; BCT; ISF (TUDortmund); IFQ (OvGU-Magdeburg) Description of the solution: • Integration of sensors to detect the force produce by the distortion in the control point • Integration of actuators to compensate the distortion • Use an incremental machining strategy in different steps • Adaption of the tool path to the deformed configuration

SCENARIO 2: DEFORMATION CS 2.2 Clamping of thin-walled curved workpieces. Description: • Control of deformation of a thin walled structural component made of Al 7075 (L=3000 mm; W=1100mm; e=2-3 mm) • Raw material: solid block • Control of clamping forces and in process thickness measurement • Worpiece turn over to machine both sides • Variable stiffness during machining ⇒ Control of the clamping foce to minimize the deformation • Control the final thickness. Error associated to deformation results in higher weight of lower stiffness • Also limited by the vibrations ⇒ optimization of process parameters Partners: • RCMT; TYC s.r.o; ROEMHELD GmbH Description of the solution: • Integration of sensors to measure the clamping forces • Control of the clamping force associated to workpiece stiffness • Establish comunication between fixture and CNC • Integration of sensors to measure the thickness

SCENARIO 2: DEFORMATION CS 2.3 Distortions in aeronautical structural parts. Description: • Control of distortions in a slender structural aeronautic component, with intensive material removal • Residual stresses from previous process and aditional stress due to clamping process • Different clamping stages to achieve an undistorted component ⇒ reduced precision, high dispersion in the results, high rejection rate • Complicated fixture due to low and changing stiffness • Currently the workpiece is supported using resin, resulting in long processes due to polymerization cicles• Currently the workpiece is supported using resin, resulting in long processes due to polymerization cicles Partners: • KALE AERO; DR. MATZAT; IK4-IDEKO Description of the solution: • Intelligent fixture to measure the clamping force and apply a controlled displacement • Two steps: first look for contact, second fix without deformation • Mathematical model of residual stress in the workpiece in each operation ⇒ Prediction of the state after each machining stage • Proposed machining process: correct and compensate the predicted distortion

SCENARIO 2: DEFORMATION CS 2.4 Machining of aircraft turbine support structures. Description: • Structural component of an aircraft turbine made of INCONEL 718 (D=1900mm; H=350mm; e=6-10mm). • Control of deformations during clamping due to distortions form previous processes (welding and heat treatment). • Turning of different flanges to meet precision and tolerances. • Rotating fixture and workpiece during machining. • Also problems associated to vibrations Partners: • ITP; STERN Hidráulica; ALAVA Ingenieros; ROEMHELD GmbH; IK4-TEKNIKER Description of the solution: • Monitoring the initial shape of the component • Sensors to measure deformations, clamping force and vibration • Actuator to adapt the fixture to the deformed configuration. Adaption of the position of the locators and clamping force • Solution for the rotation motion: Power and signal integrated a rotating workpiece- fixture (slip rings, wireless signal transmission)

SCENARIO 3: POSITIONING CS 3.1 Fixture system for workpiece adjustment and clamping with/without its predeformation. Description: • Structural component made of steel for trains (L=2500mm; H=1500mm), with previous welding processes • Reduction of the set-up time, improving the precision of the clamping process. • Achieve a right positioning taking into account the deformed shape after clamping. • Milling and drilling operations with limited precision due to deformations during clamping • Introduction of systems to reduce the vibrations during machining Partners: • RCMT; TYC s.r.o; ROEMHELD GmbH; ADAPTRONICS International Description of the solution: • Modular fixture for the leveling of the workpiece • Integration of sensors and actuators • Independant and movable supports, able to measure the force and position working in close loop

SCENARIO 3: POSITIONING CS 3.2 Semiautomatic tool reference for application on large parts Description: • Big size components with miling and drilling operations • Measuremnt of the position in the fixture/machine, and correction of the position by displacement of the supports • Avoid lack of material in the areas of interest • Reduce error from deformation during clamping • Reduce the set up time• Reduce the set up time Partners: • SORALUCE; GOIMEK; ROEMHELD GmbH; IK4-IDEKO Description of the solution: • Machine integrated vision system • Modular fixture elements integrating force control and position • Monitoring to minimize errors coming from clamping force distortions • Aplication to machines with 2 pallet stations

REMARKS (I) • Original Call: “Challenge 7 ICT for the enterprise and manufacturing” , “Objective 7.2: Equipment assessment for sensor and laser based applications” • SME with own products: Technology suppliers (Strengthen supply-side SMEs ) • Supply manufacturers with new equipment and components for improved manufacturing operations. • Foster manufacturing industry (New application areas for the products of SME)• Foster manufacturing industry (New application areas for the products of SME) • THEMATIC AREA of INTEFIX: • MACHINING PROCESS • Focus: IMPROVE THE FIXTURE (INTELLIGENCE by using sensors+actuators+control)

REMARKS (II) • EXPECTATIONS FOR NEW EXPERIMENTS: • Definition of a new Experiment/Case Study • Identify the Scenario: Vibration / Distortion / Positioning • New applications • New solutions for the intelligent fixtures• New solutions for the intelligent fixtures • Complementary the current experiments; ENHANCED IMPACT OF THE PROJECT • Include all participants necessary for the experiment • EVALUATION: • Criteria: S/T quality; Implementation; Impact • Carried out by external evaluators (At least 2 evaluations per proposal)

REMARKS (III) • MINICONSORTIUM & Countries: • Not specific requirements about the number of different countries • MINICONSORTIUM & Number of Partners: • Not specific requirements about the number of partners, at least:• Not specific requirements about the number of partners, at least: • End-user: Defining the application for the experiments • Technology supplier: systems to be integrated in the fixture • Others: integration, control… • MINICONSORTIUM & INTEFIX’s Partners: • Partners already members of the consortium can participate • EU contribution limited to 25% of the total case study (Maximum 25% of 485.000€)

REMARKS (IV) • INTEGRATION in INTEFIX: • Acceptance and Signature of the project Consortium Agreement • Coordination between case studies: Share experiences and collaboration ⇒ Methodology • Contribution to other activities: • DISSEMINATION + TRAINING + “STANDARDISATION” (if possible) + NEW PRODUCTS • 2 PM for the coordinating partner / 1 PM for other participants

REMARKS (V) • Partners must have a PIC code • Funding rates: As in FP7 • Work structured in a single WP of type RTD • SME, RTD performers, Universities: 75%• SME, RTD performers, Universities: 75% • Large Industry: 50%

More information:More information: www.intefix.eu www.i4ms.eu Contact: Oscar Gonzalo (oscar.gonzalo@tekniker.es)

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Presentation of the webinar - INTEFIX

Done WEBINAR on the Intefix Open Call You can download the presentation here: INTEFIX_Webinar_2014-03-21_v2 (1.56 MB)
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This project has received funding from the European Community''s Seventh Framework Programme (FP7-2013-NMP-ICT-FoF) under grant agreement no 609306.
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