INTElligent FIXtures for the manufacturing of low rigidity components

Grant agreement no: 609306

WEBINAR: INTEFIX OPENCALLOscar Gonzalo

21/03/2014This 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 availablestate of the art software and hardware tools (sensors, actuators, CAD/CAM/CAE, CNC, PLC, processsimulation tools,...) combined with ad-hoc ICT tools (control algorithms, simulation tools...) to controland adapt the behaviour of the fixture, resulting in the development of intelligent fixtures. Thesemethodologies 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

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CASE STUDY n

Coordinating partner

Technology supplyers

End-user

RTD performers

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C-TEC

INVENT

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MATZAT

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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-

STEERING COMMITTEEMembers to be appointed at 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

Scenario 1: Vibration

Case

Study 1

Case

Study 2

Scenario 2:

Deformation

Case

Study 1

Case

Study 2

Case

Study 3

Case

Study 4Scenario 3:

Positioning

Case

Study 1

Case

Study 2

TECHNICAL COMMITTEE OvGU/IFQ-RCMT-

IDEKODissemination: 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 18T 13.1 General analysis and definition of the fixture configuration 9T 13.2 Development of the fixture control 9T 13.3 Detailed design. Manufacturing and assembly of the test platform 6T 13.4 Test. Verification and validation 3WP 14 Case study 0.2. Open call for the Scenario 2: Deformation 18T 14.1 General analysis and definition of the fixture configuration 9T 14.2 Development of the fixture control 9T 14.3 Detailed design. Manufacturing and assembly of the test platform 6T 14.4 Test. Verification and validation 3

Year 1 Year 2 Year 3

T 14.4 Test. Verification and validation 3WP 15 Case study 0.3. Open call for the Scenario 3: Positioning 18T 13.1 General analysis and definition of the fixture configuration 9T 15.2 Development of the fixture control 9T 15.3 Detailed design. Manufacturing and assembly of the test platform 6T 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 36T 1.1 Establish INTEFIX administration and methodologies for integrating project activities 3T 1.2 Management and Coordination 36T 1.3 Administration and Support activities 36T 1.4 Open Call. Mechanism implementation 36WP 2 Training, dissemination and exploitation 36T 2.1 Training activities 36T 2.2 Dissemination strategy and activities 36T 2.3 Exploitation activities 36T 2.4 Standardization activities 36

Year 1 Year 2 Year 3

T 2.4 Standardization activities 36WP 3 Specifications 6T 3.1 General specifications 6T 3.2 Specifications of experiments in Scenario 1: Vibrations 6T 3.3 Specifications of experiments in Scenario 2: Deformations 6T 3.4 Specifications of experiments in Scenario 3: Positioning 6T 3.5 Definition of the required specifications for the OPEN CALL case studies 6WP 4 INTEFIX methodology development 12T 4.1 Methodology for cases in Scenario 1: Vibrations 12T 4.2 Methodology for cases in Scenario 2: Deformations 12T 4.3 Methodology for cases in Scenario 3: Positioning 12

SCENARIO 1: VIBRATIONCS 1.1

Identification and active damping of critical workpiece vibrations in milling of thin-walledimpellers/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 toolwear.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 unstablecutting, also including actuators to counteract thevibrations

• Use of dynamic simulations of the cutting processas 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: VIBRATIONCS 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 ofthe position and clamping force

SCENARIO 2: DEFORMATIONCS 2.1

Detection and compensation of workpiece distortions during machining of slender and thin-walledaerospace 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: DEFORMATIONCS 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: DEFORMATIONCS 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, highrejection 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 ⇒ Predictionof the state after each machining stage

• Proposed machining process: correct and compensate the predicted distortion

SCENARIO 2: DEFORMATIONCS 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 positionof 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: POSITIONINGCS 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 andposition working in close loop

SCENARIO 3: POSITIONINGCS 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 bydisplacement 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)