Innovation in manufacturing processes for metalworking production facilities

1. Innovation in manufacturing processes for metalworking production facilities Industrial Technologies 2012 Mr. Luigi Galdabini

2. Agenda Importance of sustainable manufacturing processes The competitiveness of the EU MT Industry Advanced manufacturing processes Example of R&D efforts for sustainable manufacturing Machine tool industry R&D priorities

3. Policies and strategies Europe 2020 strategy • Changes in sustainable consumption and production since 2000 indicate following*: • Only relative decoupling of resource use from economic growth; • Consumption of materials continues to rise; • Waste management improving, although generated is more hazardous waste; • There is decrease in atmospheric emissions; • Final energy consumption decreased in 2009;  • Increase of organisations certified with an environmental management system; * Measuring progress towards a more sustainable Europe- Eurostat statistical book

4. Competitiveness of the EU MT Industry • Main findings of the study • The key to competitiveness: • Innovation • Differentiation through technology • Excellence in engineering • Innovation capacity to develop new processes and products

5. Advanced manufacturing processes Production methods for complex shaped workpieces • reliable and productive planning for complex-shaped workpieces • Streamlined use of CAM systems • machining strategies • configuration of post-processors • use of measurements and measurement data evaluation to adjust machining methods • further understanding of more effective process of cutting tools for open and closed surfaces • , analysis of cutting process stability for machining with four or more axes Picture source :Nonlinear dynamics of a machining system with two interdependent delays, Alexander M. Gouskov

6. Advanced manufacturing processes Innovation of cutting tools • edge geometry • cutting stability, tool edge durability and machined surface quality • cutting stability, tool edge durability and machined surface quality • Improved cooling • simulations of tool functions in the design phase • simulations of the environmental impact of machining methods combined with particular tools *Source picture: nsmwww.eng.ohio-state.edu

7. Advanced manufacturing processes Optimum cutting conditions • optimization of cutting conditions in terms of reduced costs, maximised manufacturing productivity and improved surface quality • Prediction of tool service life • Monitoring of cutting stability, energy demands and environmental impacts • Development of mathematical models of the cutting process • Optimisation of cutting conditions, using information about the dynamic behaviour of tool • Use of environment-friendly cutting fluids and lubricants

8. Advanced manufacturing processes Machine tool mechanics and control on workpiece quality and dimensional accuracy • simplified descriptions of static, dynamic and thermal machine tool properties • NC code optimisation considering the dynamic properties of machine, spindle, drives and control system. • Research on the influence of machine tool properties and their changes with time, temperature, kinematic configuration

9. R&D efforts for sustainable manufacturing Coordinator: Tecnalia Coordinator: Fiat Research Center

10. CECIMO R&D priorities Standby Machine Envirement • The R&D priorities : • Energy efficiency of a single machine • Low energy consuming manufacturing strategies • Advance ultra-precision machines • Virtual testing and machining • Developing new techniques of metal working

11. Final conclusions • Innovation in advanced manufacturing processes to be performed through analysis of science, technology and market trends • Continuous improvement to be ensured • Monitoring of resources optimisation necessary © 2012 Fastems

12. Filip Geerts, Director General