Approach to Design and Develop Machine Tools Technologies … · 2019-01-29 · BHARAT FRITZ WERNER LTD Bharat Fritz Werner Approach to Design and Develop Machine Tools Technologies

BHARAT FRITZ WERNER LTD

Bharat Fritz Werner

Approach to Design and Develop Machine Tools Technologies and

Composite Structures

ByDr. Harshad Sonawane

Dr. Kalam Center for Innovation


Bharat Fritz Werner

A Journey Towards Excellence....

1


Strong Technical Foundation

1961: Technical and Financial Collaboration with Fritz Werner Werkzeugmaschinen GmbH, Berlin

1970: Partnership with Burckhardt & Weber, Germany

1970-Present: Fully Indian owned company

2012: Acquired Matec Maschinen GmBH

2


Over the Past 57 Years in

Machine Tool Industry

BFW’s Leadership Through Continuous and Vigorous “New Product and Technology Development”

Efforts

Market Leader for Seven Consecutive Years in Horizontal & Vertical Machining Centers and Special Purpose

Machines

3


Independent

BFW R&D Centerformed in

2014

Dr. Kalam Center for Innovation2016

4


Dr. Kalam Center for InnovationFormal Inauguration

February 2016

Formal Inauguration by

Shri. Kiran Kumar

Chairman,

Indian Space Research Organization (ISRO)

5


Mission

Basic and Applied Research &Development


Mission: Human Body Analogy

6

Skeleton Muscles Heart Brain Neural network

Health and Performance

*All figures are referred to google.com


Basic and Applied R&D in Machine Tools

Machine Tool Structures: Skeleton and MusclesHigh Speed Motorized Spindles: HeartThermally Stable Spindles & Machines: BrainCNC Systems and IoT based Management platform: Neural Network

7


R&D projects at present

Project # 9001A: Development of Epoxy Granite

Structure BFW + Academia

Project # 9001B: Development of

Composite CI Structure

BFW

Project # 9001:Alternate Materials

for Machine Tool Structures

Project # 9003:Improving thermal

stability of motorized spindles

and complete machine

Project # 9002:Development of high speed high

accuracy motorized spindles

Project #9004:Development of CNC system and

IoT based management

platform

8


Project # 9001A:

Design and Development of Epoxy Granite (EGTech) Machine tools

BHARAT FRITZ WERNER LTD 9

I: Raw Materials and Equipment

1. Granite slabs

2. Stone crusher

4. Sieve 5. Granite particles

3. Crushed slabs 6. Resin and Hardener

*Photograph courtesy PSG Tech, Coimbatore


III: Mould Preparation



II: Mixing, Pouring and Compaction

Granite particles

Resin and Hardener Concrete Mixer

Pouring Vibrating table for compaction

Epoxy granite specimens



Mechanical Characterization: Test Setups

Compressive test Split tensile test Flexural test Damping test

Cast Iron (FG 300):960 MPa

Epoxy Granite: 112 MPa

Cast Iron: 300 MPaEpoxy Granite: 28 MPa

Young’s Modulus:

Cast Iron: 135 GPa

Epoxy Granite: 30 GPa

Cast Iron: 0.001

Epoxy granite:0.02



Basic Research of Development of Epoxy Granite is then Applied to

Manufacture VMC Machine Structures


Cast Iron 3D Model Epoxy Granite 3D Model

Front Back Front Back

VMC Column


Epoxy granite casting for VMC Column


Cast Iron 3D Model Epoxy Granite 3D Model

VMC Base


Epoxy granite casting for VMC Base


Project # 9001B:

Development of Composite Cast Iron (iCTech) Machine Tools


Concept

Cast Iron Column prototype

Composite Cast Iron (iCTech) Column

Prototype

Sound/Noise proof

Moisture resistant

Chemical resistant

Stiffness/weight

Excellent damping

Higher service life

Economical

Sustainable

Desired characteristics of iCTech material


iCTech: Iron Composite Technology*

Special Concrete Variety of Minerals Polymeric Resin and Hardener

Micro-fillers

iCTech Composite*

Surfactants, Wettability agents,

etc…..

*Patented Technology


Experimental Performance Analysis

Cast Iron block iCTech block

Prototype Samples Preparation

Experimental Setup to measure natural frequencies of vibrations and damping

Impact hammer

Free-free hanging column

Accelerometer Data loggerPC


Comparison of Concrete with iCTech

(CI Column)

0.3 s

0.25 sec

(Concrete Column)

(iCTech Column)

0.029 s

0.25 s1.2X

improvement

10.3X improvement


iCTech Composite

Performance Testing for Full Scale VMCMachine


Stiffness to Weight ratio for iCTechTM Solid Structure: S/W = 12.4Improved by 4 times as compared to existing Cast Iron machines

(S/W=2.9)!


Appearance of iCTech

VMC machine(unguarded)


Performance of iCTech BMV 45+ Machine

Existing Unfilled Cast Iron Structures

Base Column Spindle Head

Improved Composite Cast Iron Structures8X Improvement

10X

3X


Existing Cast Iron VMC Performance: Complete Machine

Radial Immersion Spindle speed: 1000 RPM Feedrate: 800 mm/min

Existing VMC Machine

Machining Noise:

42-46 dB

EN 08 Steel (45 HRc)


iCTech VMC Performance: Complete Machine

Radial Immersion Spindle speed: 1000 RPM Feedrate: 800 mm/min

Composite Cast Iron VMC Machine

Machining Noise:

32-35 dB

The Machine became 3X Quieter

EN 08 Steel (45 HRc)


• Upto 5X Vibration Damping & 4X Stiffness

• Upto 3X Longer Tool Life

• Upto 5X Higher Productivity and Surface quality using Stability Lobe

Diagram

• Easy to Machine Harder Materials (60 HRc)

Performance Benefit of iCTechTM Composite Technology


Project # 9002:

Development of High-Speed High-Accuracy Motorized Spindle


3D Spindle Layout


Design Consideration for Building Spindle

• Design of two plane balancing system

• Design of Air Oil lubrication supply to individual bearing

• Spring preload arrangement for bearings

• Effective cooling circuit to reduce thermal deformation


Motor Rotor

Disc 1 Disc 2

BearingsBearings

Spacers Lock nut Lock nutSpacers

Labyrinth

Dynamic Analysis of Spindle: 3D Model


First order bending mode at 779 Hz Second order bending mode at 1520 Hz

Twisting mode at 2109 Hz Third order bending mode at 3428Hz

Longitudinal Elongation mode at 3752 Hz Fourth order bending mode at 4460 Hz

Dynamic Analysis of Spindle: FEA


Project # 9003:

Intelligent Thermal Control of Spindle and Machine


Ideal spindle Distorted spindle

Background : What is thermal robustness?

Temp. change Thermal distortion of spindle Low accuracy


Thermal robustness is achieved through three ways: reduction, control and compensation

• Intelligent Real-time Thermal Control (iRTC) module will use all three strategies and will be deployed through iRIS

Three strategies:1. Reduce thermal errors at source2. Thermal error control3. Thermal Compensation


Thermal error reduction is achieved through a novel Spindle Cooling Module (SCM)

• A novel cooling strategy called SCM is developed• SCM balances the heat dissipation in spindle with the real-

time heat generation • SCM significantly reduces thermal errors


Novel cooling results upto 50% reduction in thermal error


Compensation is performed using real-time information

The thermal distortion of a cutting point has got reduced by more than 100% after compensation


A High-speed Die and Mould Series….For Excellent Performance!


BFW….A Leader in Innovation!


BFW….A Leader in Innovation!


Thank You!

Questions?

Reach us:[email protected]: +91 9341 143 153

mailto:[email protected]

mailto:[email protected]

Documents

Approach to Design and Develop Machine Tools Technologies … · 2019-01-29 · BHARAT FRITZ WERNER LTD Bharat Fritz Werner Approach to Design and Develop Machine Tools Technologies