R&D of Machining Technologies

assoc. Prof. MSc. Jan Řehoř, Ph.D.MSc. Marek Bureš, Ph.D.

23.10.2014

INTRODUCTION OF RTI Research Programs Departments

MACHINING TECHNOLOGY The Main Directions of the R&D The Examples of Collaboration The Future on the Touch

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Content of the Presentation

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Introduction of RTIRe s e a rc h P ro g r a m s

Modern vehicles structures and their driving systems

Production machines and their modernization

Forming technologies

Machining technologies

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Introduction of RTID e p a r t m e n t s

10 New Laboratories and Testing Rooms:

Laboratory of Experimental Methods for Mech. Engineering

Strength and Fatigue Life Testing RoomTransport Vehicle Components Testing RoomVirtual Prototyping ShopExperimental Forming LaboratoryMetallographic LaboratoryMechanical Testing RoomManufacturing Technology Planning LaboratoryExperimental Machining LaboratoryMetrology Laboratory

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Machining TechnologiesT h e M a i n D i re c t i o n o f t h e R & D

Experimental Machining LaboratoryMetrology Laboratory

I. Machining and diagnosis of complex shape objects – Cutting and Forming Tools, Fixtures, Progressive Technologies, CNC Programming, Metrology and Quality

Short description:Production of a complex shape products such as molds for die casting and plastic projecting, dies, but also products of the type of crank shafts, blades of steam turbines, turbo impellers etc., bringing them many material, technological and metrological problems. The activity will be defined by a complete solution of the production chain, from research and development of new advanced technological methods of processing (eg HSC, HPC, dry and hard machining, etc.) and non-conventional technologies (Laser, Sonic, Rapid Prototyping, etc.) and their applications through the construction cutting and forming tools, strategy, motion programming tools and on-line production quality management to analyzing and assessing the resulting quality of the machined object (surface integrity). Activities will be coordinated through existing and optimization algorithms developed in parallel to the application, and at the level SW simulation.

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Machining TechnologiesI. Machining and diagnosis of complex shape objects

The design of cutting and forming tools

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The geometry and the quality of the cutting edge

Machining TechnologiesI. Machining and diagnosis of complex shape objects

Evaluation of the cutting edge wear using a differential analysis

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The optimization of cutting conditions using modern advanced machining methods – HSC, HPC, HM, DM, MQL, ....

The experimental milling of sculptured surfaces and turning in HSC regime

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Thanks to the original design of the cutting tool (Milling cutter) using advanced ceramics for HSC milling managed to increase machining productivity in many industrial applications up to 400% !!! Tool with technology was awarded..

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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The measuring instrument "HOMMEL ETAMIC T-800" can be advantageously used for profile measurement, in this case it deals the reverse engineering of the component, for which does not already exist drawing documentation.

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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An example of point scanning of a precise workpiece for automotive industry by CMM (LK - G90 C)

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Contract research (examples):

New technology for manufacturing of the exhaust protector fixture

Přípravek slouží jako ochrana držáku výfuku při svařování dalších dílů výfuku proti ulpívání odpadních produktů, které by ve výsledku značně poškozovaly silentblok. Selecting the appropriate mix of machining operations led to savings compared to the original technology by 35%. The result will be protected using proven technology in 2014.

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Contract research (examples):

New technology for manufacturing of the molds for pressing catalyst

Jedná se o návrh a ověření celkové technologie obrobení formy pro zalisování dílů pláště výfukového tlumiče. Celkový čas výroby byl zkrácen z 65 hod na 40 hod. Ověřená technologie je registrována zn. 8/TECH/KTO/2013

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Manufacturing Technology Planning Laboratory

II. Virtual Technological Preparation of Production

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• The ergonomics in repeated manufacturing of small components

• The ergonomics in the production of the large units

• Production Layout

• Simulation and models creation

Machining TechnologiesI. Virtual Technological Preparation of Production

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• Improvement of the work performance• Decrease production of bad products• Decrease incapacity and disease from the

career• Improvement physical and psychical

condition of the employees.• Minimization psychical and physical fatigue• Improvement of the psychological climate at

the workplace• The growth company

Major benefits

The ergonomics in repeated manufacturing of small components

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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The ergonomics in the production of the large units

• Productivity improvement• Planning the steps in the individual operations• Simulate the workers activities.• Creating a virtual models of workplace with accurate biomechanical

human model• Detection load of man at his work with using many ergonomics

analyses• Feasibility verification of work activities.

Using these rationalization measures is possible:

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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The ergonomics in the production of the large units

Wrong

Good location

The collision of move

• Impossibility locomotives rotation around its axis – interfere energy distribution

• Difficult availibility of worker on the welded places – interfere energy distribution

• Problematic of the workers overload

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Production Layout

• The space saving• Manipulation reduction.• Minimization logistics activities• Updating and creating the current layout of the production system• Today is usually in the interactive 3D view.• The analysis of the production system with regard to the material creation and other

material flows.• The calculation of the required number of sites storage in production

Solutions target and deployment:

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Simulation and models creation

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The simulation should as first verify intended organizational and the measures control and should eliminate the incorrect decision, which it could lead to the problems in the company. Furthermore is possible:• Production increase• Position abate (worker, machine)• Reduce of worker numbers• Risks decrease to go back on terms of contract completion• The ensure faster to start-up of new production• The ensure faster to start-up of the new transport system.

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Universal Micro-Tool Grinder

Multi-task turning center

Milling machine for machining of very hard non-metallic materials

Rapid prototyping machine - metals

Machining TechnologiesI. Machining and diagnosis of complex shape objects

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Machining TechnologiesPartners

ABF a.s. Praha – mediální partner, veletrh For IndustryAXA CNC stroje s.r.o. Hořovice – výrobce obráběcích strojůSHM s.r.o. Šumperk – depozice vrstev na nástrojeGÜHRING s.r.o. Plzeň-Sulkov – výrobce nástrojů pro obráběníGTW Bearings s.r.o. – výrobce kompozicových ložisekISCAR ČR s.r.o. - distributor nástrojů pro obráběníSANDVIK CZ s.r.o. – distributor nástrojů pro obráběníHOFMEISTER s.r.o. – výrobce nástrojů pro obráběníPILSEN TOOLS s.r.o. – výrobce nástrojů a nářadíSaint-Gobain Sekurit ČR s.r.o. Hořovice – Výrobce autoskel Škoda Power, a.s. Plzeň – výroba energetických zařízeníSolidVision, s.r.o. Brno – CAD/CAM/CAE/PDM systémy Strojírna TYC s.r.o. Mýto – výrobce obráběcích strojůSVAZ STROJÍRENSKÉ TECHNOLOGIE – mediální a odborná podpora ČESKÁ SPOLEČNOST PRO JAKOST, o.s. – odborná podporaČESKÁ SPOLEČNOST STROJÍRENSKÉ TECHNOLOGIE – mediální a odborná podporaMM průmyslové spektrum – vydavatel odborných časopisůTechnometra a.s. Praha – výroba součástí pro letecký průmyslHAM-FINAL s.r.o. – výrobce nástrojů pro obráběníPramet Šumperk a.s. – výrobce nástrojů pro obráběníAsseco Solutions a.s. – informační systémyRobert BOSCH, a.s. ČB – výrobce systémů převážně v segmentu AutomotiveASTRO KOVO Plzeň – výrobce dílů převážně rotačního charakteruInnomia, a.s. Jaroměř – 3D tisk plastů a kovůCompoTech, s.r.o. Sušice – Výrobce kompozitních materiálů a výrobků

Thank you for your attention!