FFI Robust machining

Purpose and goal

New environmentally friendly and safe vehicles require light weight materials with higher strength and, as a consequence, tougher machining conditions and increased machining robustness. The very complex system of machine tool, fixture, cutting tools and the machined part is almost impossible to model without complementary measurements of the real system. New ideas and technologies to improve the dynamic and static capability of machining systems are based on model identification, Poincaré map techniques, double ball bar with integrated load capability and tracking laser interferometry and an innovative high damping interface. New ideas for knowledge reuse will enable better utilization of collected data during the lifecycle of the machine. The new concepts and technologies should be further developed and tested in industrial cases. Proposals for industrial tests and analyze procedures, actions and measures to increase the stiffness and robustness of the system will be developed.

Expected results and effects

Productivity: Due to added damping at the joint interfaces, machining system damping will be considerably higher than the conventional systems and thereby more aggressive machining parameters can be used to produce quality products at a much faster rate and with minimal damage to cutting tools cheaper production with shorter lead times. Reliability: Due to a more stable operation condition, up to 100% improvement in product non-conformance rejection and 7590 % reduction in machine tool breakdowns and tool breakage can be achieved. Lead time for design and use: Up to 5075% reduction in machine tool lead time due to concurrent design and development process, 25% reducing in manufacturing lead time trough stable operation and monitoring strategies. Energy: Attributed to the controlled and stable operation condition for high precision machining, the required quality of the operation can be achieved in a single operation in which rework rates will be minimized and reduction of process steps such as intermediate processes to improve surface finishes like that of rough machining, grinding operations, inspections, etc become unnecessary. This can result in an energy saving by 3060%. Improvement of work environment: Up to 90% reduction in process noise and hence workshops will be both environment and worker friendly.

Planned approach and implementation

To start with, the following industrial cases will be studied in the project: 1) Gear cutting machine at Scania in Södertälje 2) 5-axis machining center at Saab in Linköping 3) Machining center at PTC in Trollhättan 4) Turning center at Leax Falun in Falun Depending on the results, additional case studies will be decided later on by the project steering committee. The project is divided into four work packages: WP1 Project coordination and result dissemination WP2 Machining system condition testing and monitoring WP3 Machining system modeling and reuse of manufacturing experience WP4 Machining system design high damping interface (HDI) system.