GAP - Clean alternative technology to
chemical milling: demonstration of technical,
environmental and economic performance of
mechanical milling for the machining of
complex shaped panels used in the
aeronautical and space industries - GAP
(Green Advanced Panels) project
LIFE05 ENV/F/000062
Project description Environmental issues Beneficiaries Administrative data R e a d m o r e Contact details:
Project Manager: René PANCZUK
Tel: +33 4 76332610
Fax: +33 4 76096744
Email: info@DUFIEUX-industrie.com
Project description:
Background
Complex shaped panels used in the aeronautical and space industries are made
by chemical milling. This process is frequently used on double-curvature parts
requiring weight reduction or in parts made from alloys of titanium, tin, nickel,
cobalt and magnesium. Main environmental problem associated with the process
is the production of a large amount of slurry that are currently disposed of by
burning in cement kilns. The process also uses large amounts of water and
solvents. Mechanical milling represents a better environmental alternative to the
proc ess. Objectives
The beneficiary, DUFIEUX Industrie, has made a technological leap in machine
tool design that enables complex shaped panels to be mechanically
manufactured with at least the same level of efficiency as chemical milling. In
this eco-friendly process, the only by-products are aluminium chips that are
recycled as secondary raw material. The project aims to demonstrate the
performance of the mechanical milling with the partnership of Airbus. Milled
panels are important for the plane industry needs because they allow aircrafts to
carry greater weight. As a result, the panels significantly reduce oil consumption
without impairing the rigidity of the plane. Results
The project demonstrated the technical capacity of mechanical milling of double
curvature panels. It designed a model "F5X1 demonstrator" that could rapidly
replace the chemical milled panels with the new mechanical ones. The model can
process panels of 6.5 m long and 2.5 m wide. It is believed that it can be
developed to process panels of 10 m long and 4 m wide. The project had to overcome existing technical problems associated with
mechanical milling. It was difficult to achieve accurate machining, sufficiently
good dynamic performance of the machine and quality of the controls and
spindles. The project overcame these difficulties by incorporating several
technical innovations in the F5X1 demonstrator including:
High-speed, high-performance electric spindles.
Expertly designed “mecatronic” systems and optimised machine design.
Digital closed-loop control management and introduction of induction
motors.
Digital machine control.
The beneficiary added two major innovations to these technologies: "100C" milling head allowing an optimised tool path with limited amplitude
during the machining process.
The mecatronic support: an intelligent support mounted on a 6 axis module
facing the tool and perfectly synchronized with the 6 axis milling head.
Patents have been registered for both these technological innovations. As a
result of such technological innovations, the clean technology implemented
in the GAP project pilot demonstration unit is a world first and a major
technological step for the aeronautical and space industry. Airbus is already building a plant that would produce different size units
according to the panels needed. Mechanical milling will replace the chemical
milling for all panels produced by Airbus. The beneficiary is in contact with
the IPPC bureau in Spain for the technology used in the project to become a
Best Available Technology. Potential clients are interested in using the
process for other materials such as titanium or carbon fibre. The economic and environmental benefits of replacing chemical milling
with mechanical milling at Airbus’s European sites are estimated by the
beneficiary as follows: a reduction in the required quantity of rinsing water by 225 000 m3 per year,
a reduction in the quantity of waste produced by more than 16 000 tons,
total elimination of sludge processing and associated risks from hydrogen
emission,
a 50 % reduction in operating costs,
a 20 % reduction in the cost per machined part,
a 50 % reduction in the production cycle time,
a 57 % reduction in electricity consumption.
This project has been selected as one of the 21 "Best" LIFE Environment projects in
2 0 0 7 - 2 0 0 8 Top
Environmental issues addressed:
Themes
Industry-Production - Metal industry
Environmental management - Cleaner technologies
Industry-Production - Engines - Machinery - Vehicles
Keywords
clean technology‚ heavy metal‚ coating‚ air transportation Target EU Legislation
Industry and Product Policy
Directive 96/61 - Integrated Pollution Prevention and Control (IPPC)
(24.09.1996)
Natura 2000 sites
Not applicable
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Beneficiaries:
Coordinator
Type of organisation
Description
Partners
Dufieux Industrie
SME Small and medium sized enterprise
DUFIEUX Industrie is a SME based near
Grenoble (France). Its design office has both the
expertise and the most powerful tools for
modelling the structure of machine tools. Airbus, France Top
Administrative data:
Project reference
LIFE05 ENV/F/000062
Duration
Total budget
EU contribution
Project location
15-JAN-2005 to 30-JUN -2007
8,149,549.00 €
1,903,762.00 €
Pays de la Loire(France),Rhône-Alpes(France)
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Read more:
Publication: Layman report
Title: Layman report (EN/FR) Year: 2007 No of
pages: 2 Top
Project description Environmental issues Beneficiaries Administrative data R e a d m o r e