Eureka S0307 MINDESTRESS

Important results from the project

Shape changes during processing, machining, are a common problem for the manufacturing industry. This project intended to investigate this problem by developing a toolbox to find the root causes of the shape changes and to take appropriate measures to correct the shape error. The project met its objective and has developed an approach to find the root cause with support of a toolbox with various analysis tools, measuring equipment and FE models, as well as methods to find suitable measures to minimize form defects.

Expected long term effects

Through case studies, the project has identified a common problem of meeting strict tolerance requirements, which today must be remedied with costly and time-consuming processing. The results and lessons learned from this project are that the heat treatment has been identified as a clear root cause of shape changes, but that this can be dealt with in a machining operation if correct setup of the part is done during machining. The developed working method and toolbox will be used and developed at the companies and in future research projects.

Approach and implementation

The project was carried out in various case studies with the lessons learned identifying the heat treatment as a clear root cause of shape changes, but that this can be handled in a machining operation if correct tensioning and alignment of the part is done during machining. But even the heat treatment can be improved by optimizing process parameters, material selection, etc. For critical components, a smaller amount of processing in the heat-treated state should be considered. In summary, the project showed the importance of the mapping work to produce the necessary action plan.