INTEFIX - I4MS Information Day - 22/11 Bilbao (Spain)
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INTElligent FIXtures for the manufacturing of low rigidity components Grant agreement no: 609306 GENERAL PRESENTATION Kick-off meeting 15-16/06/2013 This project is part of the I4MS initiative
INTEFIX - I4MS Information Day - 22/11 Bilbao (Spain)
INTEFIX aims to increase the performance of the machining processes by the use of intelligent fixture systems, allowing the monitoring, control and adaptation of the process to obtain suitable results according to precision, quality and cost requirements.
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1. INTElligent FIXtures for the manufacturing of low rigidity
components Grant agreement no: 609306 GENERAL PRESENTATION This
project is part of the I4MS initiative Kick-off meeting
15-16/06/2013
2. PROJECT DATA Partners: 22 Starting date: July 2013 Ending
date: June 2016 Duration: 3 years/36 month Budget: 9.639.391 EC
contribution: 7.499.998 (including the OPENCALL) OPENCALL: EC
contribution: 1.500.000 Tentative call date: february/march 2014
Minimum number of new experiments: 3
3. INTRODUCTION Manufacturing industry needs: Precise machining
of medium and big size parts (aeronautic, space or energy sectors)
Increase the performance of the machining processes Conventional
functions of fixtures: securely hold and accurately locate the
workpiece INTEFIX Use of intelligent fixture systems, allowing the
monitoring, control and adaptation of the process to obtain
suitable results according to precision, quality and cost
requirements Additional functions of INTEFIX fixtures: Reduce the
impact of the deformations, vibrations and distortions in the
workpiece during processing CONCEPTS: Mechatronic/Adaptronic
systems based on sensors, actuators, control algorithms, simulation
tools Tuneable behaviour of the Machining system
(machine-fixture-workpiece) Use of modular elements Applicable to
other processes such as welding repair, assembly, etc.
4. CHALLENGES OF INTELLIGENT FIXTURES The development of
adaptive, efficient and intelligent fixtures faces different
challenges: To provide high accuracy and repeatability, being the
fixtures tolerances 20% to 50% of the workpieces tolerances. To be
safe and reliable, minimizing clamping variability and prevent
clamping errors that lead to scraps and rejected parts. To maintain
the workpieces references and provide a high degree of
repeatability despite the use of active elements (displacements).
To be automatic instead of manual, in order to reduce the process
time and errors. To be cost-effective, taking into account the
higher cost associated to sensors, actuators and electronics. To
reduce the set-up time for a new configuration/component. To be
modular (reconfiguration, disassembling and reusing). To be robust,
durable and resistant to withstand the severe conditions during
machining process (chips, cutting fluids, vibrations...). To be
able to identify the process limitations (vibrations,
deflections...) and to adapt the behavior.
5. ADVANTAGES OF INTELLIGENT FIXTURES The possibility of use an
active intelligent modular fixture allows: Change the fixture
behavior (static and dynamic) by modifying the position, clamping
force, modal frequencies, damping ratio or stiffness of the whole
system (machine-fixture-workpiece). Mitigation or avoidance of
process static problems (position, deflections, distortions...) and
dynamic problems (chatter, forced vibrations) during machining.
Dynamic control of the fixture based on sensors (laser,
piezoelectric, MEMS, FBG sensors...) and actuators (hydraulic,
pneumatic, mechanical...). Increased process performance (Precision
and quality, MRR, tool life, ecoefficiency). Increased process
control (monitoring, mechatronic and adaptronic systems...).
Reduction of manufacturing time and scrap. Reuse of fixture
components and easy adaptation to new workpiece geometry (using
zero point clamping, modular elements) .
6. MAIN OBJECTIVE The INTEFIX project aims to establish fixture
design methodologies taking advantage of the available state of the
art software and hardware tools (sensors, actuators, CAD/CAM/CAE,
CNC, PLC, process simulation tools,...) combined with ad-hoc ICT
tools (control algorithms, simulation tools...) to control and
adapt the behaviour of the fixture, resulting in the development of
intelligent fixtures. These methodologies will be based on the use
of modular elements to obtain highly configurable, fast, accurate
and durable fixture systems. ACTUATORS SENSORS PROCESS, MACHINE
TOOL and FIXTURE ACTUATION MONITORING INTEFIX Experiments State of
the art systems Adaptive fixture Modular elements Methodology
Integration Intelligent fixtures QUALITY, PRECISION, PERFORMANCE,
EFFICIENCY, SUSTAINABILITY The INTEFIX project development is based
in three pillars: Monitoring / Acting / Control Fixture
behaviour
7. SPECIFIC OBJECTIVES (1/2) The project aims at the
installation of intelligent fixtures and the development of
assessment experiments to probe their suitability in improving
machining processes. Reduction of 50% in the development time of
fixtures for complex components. Reduction of 50% workpiece setup
time and increasing the machine operator safety. Development of
intelligent and adaptable fixtures able to respond against
undesirable forces, vibrations and displacements coming from
material removal process related changes. Application of adaptronic
concepts to the development of fixtures and fixture elements for
machining operations. Application of state of the art sensors
(laser, piezoelectric), conventional actuators (Pneumatic,
hydraulic) and alternative actuators (magneto-rheological,
piezoelectric actuators). Use of advanced materials (composite
materials) to improve the fixture behaviour (Damping), weight and
cost. Development of monitoring and control strategies and
algorithms to obtain a suitable and fast response of the
intelligent fixture. Integration of the fixture control system in
the CNC or PLC to obtain the monitoring information available
(machine internal signals of power, torque, axes positions...) and
to modify the cutting conditions. Development of a solution for the
modularization and standardization of the sensing and acting
modules, allowing accurate and repeatable positioning of the work
piece (zero-point clamping based systems).
8. SPECIFIC OBJECTIVES (2/2) Improvement of 15% of machining
performance due to the avoidance of vibrations and chatter imposed
limitations. Improved reliability of the machining operation due to
the active control of vibrations, deflections and distortions.
Leading to a reduction of rejections of 70-90%. In depth knowledge
about the performance of different state of the art sensors and
actuators for the improvement of machining processes. Adaption of
state of the art simulation tools (chatter, forces, modes,
deformations...) to predict the behaviour of the fixture subjected
to the process loads. Two alternatives for the use of the
intelligent fixtures: a) Real time fixture adaption from the
process monitoring data, or b) Predefined fixture adaptation from
the pre-process simulation. Definition of suitable and adapted CNC
tool path attending to the process conditions and workpiece-fixture
behaviour. Integration of the INTEFIX systems for their validation
in selected machining applications.
9. STRUCTURE OF THE PROJECT The structure of the project is
based in a series of CASE STUDIES for which suitable solutions will
be developed combining sensors, actuators, machining technology and
ICT technologies. The case studies are divided in three application
scenarios: SCENARIO 1: VIBRATION. Workpieces with problems of
vibrations during machining. SCENARIO 2: DEFORMATION. Workpieces
with problems of deflections/distortions during machining. SCENARIO
3: POSITIONING. Workpieces with problems of reference setting.
SCENARIO 2 DEFORMATIONS SCENARIO 3 POSITIONING WP 7 CS 2.1 WP 11 CS
3.1 WP 6 CS 1.2 WP 13 CS 0.1 CASE STUDY n Coordinating partner
Technology supplyers RTD performers End-user WP 9 CS 2.3 WP 13 CS
3.2 WP 10 CS 2.4 WP14 CS 0.2 WP15 CS 0.3 WP 8 CS 2.2 CASE STUDY n
Coordinating partner CASE STUDY n CASE STUDY n Coordinating partner
Coordinating partner Technology supplyers RTD performers End-user
Technology supplyers RTD performers End-user WP4: INTEFIX
methodology development Technology supplyers RTD performers
End-user RESULTS WORK PACKPAGES WP1 Management Case studies from
OPEN CALL SCENARIO 1 VIBRATIONS WP 5 CS 1.1 OPEN CALL WP2 Training,
dissemination and exploitation WP3: Specifications CASE STUDY n
Coordinating partner Technology supplyers RTD performers
End-user
10. SCENARIO 1: VIBRATIONS Case Study 1.1. Identification and
active damping of critical workpiece vibrations in milling of
thin-walled impellers/blisks. The objective is to limit the
vibrations in components with blade features in order to obtain a
more precise process with suitable surface finishing. This
objective will be achieved by the introduction of sensors and
active elements commanded by control algorithms feed by advanced
process modelling software tools. Case Study 1.2. Turning of low
pressure turbine casing. The objective is the improvement of the
turning performance by using sensors to detect the presence of
undesired vibrations and actuators to modify the fixture-workpiece
dynamic behaviour.
11. SCENARIO 2: DEFORMATIONS (1/2) Case Study 2.1. Detection
and compensation of workpiece distortions during machining of
slender and thin-walled aerospace parts. The objective is the
automated correction of workpiece distortions due to the material
removal and residual stress state change, and the modification of
the fixture configuration (force and position) to minimize the
deformation related to the clamping process. Case Study 2.2.
Clamping of thin-walled curved workpieces. The objective is the
minimization of deformations of the workpiece during the machining
due to changeable stiffness by simultaneous measurement and
correction of errors caused by the cutting process and fixturing
elements.
12. SCENARIO 2: DEFORMATIONS (2/2) Case Study 2.3. Distortions
in aeronautical structural parts. The objective is counteract the
distortions of workpieces with huge material removal and residual
stress relieving using the fixture elements to control the position
and the clamping force. Case Study 2.4. Machining of aircraft
turbine support structures. The objective is control the
deformation of complex geometry welded structure in the subsequent
machining operations. It also covers the introduction of damping to
avoid the vibrations associated to the modified clamping conditions
associated to the distortions.
13. SCENARIO 3: POSITIONING Case Study 3.1. Fixture system for
workpiece adjustment and clamping with/without its predeformation.
The objective is the control of the positioning of the workpiece
during the set-up process maintaining the relative references, and
taking into account the deformations associated to the own weight.
Case Study 3.2. Semiautomatic tool reference for application on
large parts. The objective is the introduction of fixtures able to
measure and displace the workpiece to optimize its position in
order to avoid problems related to lack of base material in certain
zones.
14. More information: www.intefix.eu www.i4ms.eu Contact: Oscar
Gonzalo ([email protected])