R&D of Machining Technologies

1. R&D of Machining Technologies assoc. Prof. MSc. Jan Řehoř, Ph.D. MSc.Marek Bureš, Ph.D. 23.10.2014

2. Content of the Presentation • INTRODUCTION OF RTI • ResearchPrograms • Departments • MACHINING TECHNOLOGY • The Main Directions of the R&D • The Examples of Collaboration • The Future on the Touch

3. Introduction of RTI Research Programs • Production machines and their modernization • Modern vehicles structures and their driving systems • Machining technologies • Forming technologies

4. Introduction of RTI Departments 10 New Laboratories and Testing Rooms: • Laboratory of Experimental Methods for Mech. Engineering • Strength and Fatigue Life Testing Room • Transport Vehicle Components Testing Room • Virtual Prototyping Shop • Experimental Forming Laboratory • Metallographic Laboratory • Mechanical Testing Room • Manufacturing Technology Planning Laboratory • Experimental Machining Laboratory • Metrology Laboratory

5. Machining Technologies • The Main Direction of the R&D 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. • Experimental Machining Laboratory • Metrology Laboratory

6. Machining Technologies • I. Machining and diagnosis of complex shape objects The design of cutting and forming tools

7. Machining Technologies • I. Machining and diagnosis of complex shape objects The geometry and the quality of the cutting edge Evaluation of the cutting edge wear using a differential analysis

8. Machining Technologies • I. Machining and diagnosis of complex shape objects 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

9. Machining Technologies • I. Machining and diagnosis of complex shape objects 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..

10. Machining Technologies • I. Machining and diagnosis of complex shape objects 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.

11. Machining Technologies • I. Machining and diagnosis of complex shape objects An example of point scanning of a precise workpiece for automotive industry by CMM (LK - G90 C)

12. Machining Technologies • I. Machining and diagnosis of complex shape objects 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.

13. Machining Technologies • I. Machining and diagnosis of complex shape objects 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

14. Machining Technologies • I. Virtual Technological Preparation of Production II. Virtual Technological Preparation of Production • The ergonomics in repeated manufacturing of small components • The ergonomics in the production of the large units • Production Layout • Simulation and models creation • Manufacturing Technology Planning Laboratory 14

15. Machining Technologies • I. Machining and diagnosis of complex shape objects Theergonomics in repeatedmanufacturingofsmallcomponents Major benefits • Improvementofthework performance • Decreaseproductionofbadproducts • Decreaseincapacity and diseasefromthecareer • Improvementphysical and psychicalconditionoftheemployees. • Minimizationpsychical and physicalfatigue • Improvementofthepsychologicalclimateattheworkplace • Thegrowthcompany

16. Machining Technologies • I. Machining and diagnosis of complex shape objects Theergonomics in theproductionofthelargeunits Using these rationalization measures is possible: • Productivityimprovement • Planningthesteps in theindividualoperations • Simulatetheworkersactivities. • Creating a virtualmodelsofworkplacewithaccuratebiomechanicalhuman model • Detection load of man at his work with using many ergonomics analyses • Feasibilityverificationofworkactivities.

17. Machining Technologies • I. Machining and diagnosis of complex shape objects Theergonomics in theproductionofthelargeunits • Thecollisionofmove • Impossibility locomotives rotation aroundits axis – interfereenergydistribution • Difficultavailibility of worker on the welded places – interfereenergydistribution • Problematic of the workers overload Goodlocation Wrong

18. Machining Technologies • I. Machining and diagnosis of complex shape objects Production Layout Solutions target and deployment: • Thespacesaving • Manipulationreduction. • Minimizationlogisticsactivities • 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

19. Machining Technologies • I. Machining and diagnosis of complex shape objects Simulation and modelscreation 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. Furthermoreispossible: • Productionincrease • Positionabate (worker, machine) • Reduceofworkernumbers • 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. 19

20. Machining Technologies • I. Machining and diagnosis of complex shape objects Universal Micro-ToolGrinder Rapid prototypingmachine - metals Multi-taskturning center Millingmachineformachiningof very hard non-metallicmaterials 20

21. Machining Technologies • Partners ABF a.s. Praha – mediální partner, veletrh ForIndustry AXA CNC stroje s.r.o. Hořovice – výrobce obráběcích strojů SHM s.r.o. Šumperk – depozice vrstev na nástroje GÜHRING s.r.o. Plzeň-Sulkov – výrobce nástrojů pro obrábění GTW Bearings s.r.o. – výrobce kompozicových ložisek ISCAR ČR s.r.o. - distributor nástrojů pro obrábění SANDVIK CZ s.r.o. – distributor nástrojů pro obrábění HOFMEISTER s.r.o. – výrobce nástrojů pro obrábění PILSEN TOOLS s.r.o. – výrobce nástrojů a nářadí Saint-GobainSekurit ČR s.r.o. Hořovice – Výrobce autoskel Škoda Power, a.s. Plzeň – výroba energetických zařízení SolidVision, s.r.o. Brno – CAD/CAM/CAE/PDM systémy Strojírna TYC s.r.o. Mýto – výrobce obráběcích strojů SVAZ STROJÍRENSKÉ TECHNOLOGIE – mediální a odborná podpora ČESKÁ SPOLEČNOST PRO JAKOST, o.s. – odborná podpora ČESKÁ SPOLEČNOST STROJÍRENSKÉ TECHNOLOGIE – mediální a odborná podpora MM průmyslové spektrum – vydavatel odborných časopisů Technometra a.s. Praha – výroba součástí pro letecký průmysl HAM-FINAL s.r.o. – výrobce nástrojů pro obrábění Pramet Šumperk a.s. – výrobce nástrojů pro obrábění AssecoSolutions a.s. – informační systémy Robert BOSCH, a.s. ČB – výrobce systémů převážně v segmentu Automotive ASTRO KOVO Plzeň – výrobce dílů převážně rotačního charakteru Innomia, a.s. Jaroměř – 3D tisk plastů a kovů CompoTech, s.r.o. Sušice – Výrobce kompozitních materiálů a výrobků 21

22. Thank you for your attention!