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Innovation in manufacturing processes for metalworking production facilities. Industrial Technologies 2012 Mr. Luigi Galdabini. Agenda. Importance of sustainable manufacturing processes The competitiveness of the EU MT Industry Advanced manufacturing processes

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innovation in manufacturing processes for metalworking production facilities

Innovation in manufacturing processes for metalworking production facilities

Industrial Technologies 2012

Mr. Luigi Galdabini

agenda
Agenda

Importance of sustainable manufacturing processes

The competitiveness of the EU MT Industry

Advanced manufacturing processes

Example of R&D efforts for sustainable manufacturing

Machine tool industry R&D priorities

policies and strategies
Policies and strategies

Europe 2020 strategy

  • Changes in sustainable consumption and production since 2000 indicate following*:
  • Only relative decoupling of resource use from economic growth;
  • Consumption of materials continues to rise;
  • Waste management improving, although generated is more hazardous waste;
  • There is decrease in atmospheric emissions;
  • Final energy consumption decreased in 2009; 
  • Increase of organisations certified with an environmental management system;

* Measuring progress towards a more sustainable Europe- Eurostat statistical book

competitiveness of the eu mt industry
Competitiveness of the EU MT Industry
  • Main findings of the study
  • The key to competitiveness:
    • Innovation
    • Differentiation through technology
    • Excellence in engineering
    • Innovation capacity to develop new processes and products
advanced manufacturing processes
Advanced manufacturing processes

Production methods for complex shaped workpieces

  • reliable and productive planning for complex-shaped workpieces
  • Streamlined use of CAM systems
  • machining strategies
  • configuration of post-processors
  • use of measurements and measurement data evaluation to adjust machining methods
  • further understanding of more effective process of cutting tools for open and closed surfaces
  • , analysis of cutting process stability for machining with four or more axes

Picture source :Nonlinear dynamics of a machining system with two interdependent delays, Alexander M. Gouskov

advanced manufacturing processes1
Advanced manufacturing processes

Innovation of cutting tools

  • edge geometry
  • cutting stability, tool edge durability and machined surface quality
  • cutting stability, tool edge durability and machined surface quality
  • Improved cooling
  • simulations of tool functions in the design phase
  • simulations of the environmental impact of machining methods combined with particular tools

*Source picture: nsmwww.eng.ohio-state.edu

advanced manufacturing processes2
Advanced manufacturing processes

Optimum cutting conditions

  • optimization of cutting conditions in terms of reduced costs, maximised manufacturing productivity and improved surface quality
  • Prediction of tool service life
  • Monitoring of cutting stability, energy demands and environmental impacts
  • Development of mathematical models of the cutting process
  • Optimisation of cutting conditions, using information about the dynamic behaviour of tool
  • Use of environment-friendly cutting fluids and lubricants
advanced manufacturing processes3
Advanced manufacturing processes

Machine tool mechanics and control on workpiece quality and dimensional accuracy

  • simplified descriptions of static, dynamic and thermal machine tool properties
  • NC code optimisation considering the dynamic properties of machine, spindle, drives and control system.
  • Research on the influence of machine tool properties and their changes with time, temperature, kinematic configuration
r d efforts for sustainable manufacturing
R&D efforts for sustainable manufacturing

Coordinator: Tecnalia

Coordinator: Fiat Research Center

cecimo r d priorities
CECIMO R&D priorities

Standby

Machine Envirement

  • The R&D priorities :
  • Energy efficiency of a single machine
  • Low energy consuming manufacturing strategies
  • Advance ultra-precision machines
  • Virtual testing and machining
  • Developing new techniques of metal working
final conclusions
Final conclusions
  • Innovation in advanced manufacturing processes to be performed through analysis of science, technology and market trends
  • Continuous improvement to be ensured
  • Monitoring of resources optimisation necessary

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