R&D of Machining
Technologies
assoc. Prof. MSc. Jan Řehoř, Ph.D.
MSc. Marek Bureš, Ph.D.
23.10.2014
Content of the Presentation
 INTRODUCTION OF RTI
 Research Programs
 Departments
 MACHINING TECHNOLOGY
 The Main Directions of the R&D
 The Examples of Collaboration
 The Future on the Touch
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I n t r o d u c t i on o f R T I
Research Programs
 Modern vehicles structures and
their driving systems
 Forming
technologies
 Production machines and their
modernization
 Machining
technologies
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I n t r o d u c t i on o f R T I
Departments
10 New Laboratories and Testing Rooms:
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Laboratory of Experimental Methods for Mech. Engineering
Strength and Fatigue Life Testing Room
Transport Vehicle Components Testing Room
Virtual Prototyping Shop
Experimental Forming Laboratory
Metallographic Laboratory
Mechanical Testing Room
Manufacturing Technology Planning Laboratory
Experimental Machining Laboratory
Metrology Laboratory
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M a c h i n i n g Te c h n o l o g i e s
The Main Direction of the R&D
I. Machining and diagnosis of complex shape objects –
Cutting and
Forming Tools, Fixtures, Progressive Technologies, CNC Programming, Metrology and Quality
Short description:
Production of a complex shape products such as molds for die casting and plastic
projecting, dies, but also products of the type of crank shafts, blades of steam turbines,
turbo impellers etc., bringing them many material, technological and metrological
problems. The activity will be defined by a complete solution of the production chain,
from research and development of new advanced technological methods of processing
(eg HSC, HPC, dry and hard machining, etc.) and non-conventional technologies (Laser,
Sonic, Rapid Prototyping, etc.) and their applications through the construction cutting
and forming tools, strategy, motion programming tools and on-line production quality
management to analyzing and assessing the resulting quality of the machined object
(surface integrity). Activities will be coordinated through existing and optimization
algorithms developed in parallel to the application, and at the level SW simulation.
 Experimental Machining Laboratory
 Metrology Laboratory
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The design of cutting and forming tools
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The geometry and the quality
of the cutting edge
Evaluation of the cutting edge wear using
a differential analysis
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The optimization of cutting conditions using modern advanced
machining methods – HSC, HPC, HM, DM, MQL, ....
The experimental milling of sculptured surfaces and turning in HSC regime
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Thanks to the original design of the cutting tool (Milling cutter) using advanced
ceramics for HSC milling managed to increase machining productivity in many
industrial applications up to 400% !!! Tool with technology was awarded..
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The measuring instrument "HOMMEL ETAMIC T-800" can be advantageously used for profile
measurement, in this case it deals the reverse engineering of the component, for which does
not already exist drawing documentation.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
An example of point scanning of a precise workpiece for automotive
industry by CMM (LK - G90 C)
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Contract research (examples):
New technology for manufacturing of the exhaust protector fixture
Přípravek slouží jako ochrana držáku výfuku při svařování dalších dílů výfuku proti ulpívání
odpadních produktů, které by ve výsledku značně poškozovaly silentblok. Selecting the
appropriate mix of machining operations led to savings compared to the original technology by
35%. The result will be protected using proven technology in 2014.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Contract research (examples):
New technology for manufacturing of the molds for pressing catalyst
Jedná se o návrh a ověření celkové technologie obrobení formy pro zalisování dílů pláště
výfukového tlumiče. Celkový čas výroby byl zkrácen z 65 hod na 40 hod. Ověřená
technologie je registrována zn. 8/TECH/KTO/2013
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M a c h i n i n g Te c h n o l o g i e s
I. Virtual Technological Preparation of Production
II. Virtual Technological Preparation of Production
• The ergonomics in repeated manufacturing of small components
• The ergonomics in the production of the large units
• Production Layout
• Simulation and models creation
 Manufacturing Technology Planning Laboratory
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The ergonomics in repeated manufacturing of small components
Major benefits
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Improvement of the work performance
Decrease production of bad products
Decrease incapacity and disease from the
career
Improvement physical and psychical
condition of the employees.
Minimization psychical and physical fatigue
Improvement of the psychological climate at
the workplace
The growth company
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The ergonomics in the production of the large units
Using these rationalization measures is possible:
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Productivity improvement
Planning the steps in the individual operations
Simulate the workers activities.
Creating a virtual models of workplace with accurate biomechanical
human model
Detection load of man at his work with using many ergonomics
analyses
Feasibility verification of work activities.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
The ergonomics in the production of the large units
The collision of move
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Impossibility locomotives rotation around its axis –
interfere energy distribution
Difficult availibility of worker on the welded places –
interfere energy distribution
Problematic of the workers overload
Good
location
Wrong
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Production Layout
Solutions target and deployment:
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The space saving
Manipulation reduction.
Minimization logistics activities
Updating and creating the current layout of the production system
Today is usually in the interactive 3D view.
The analysis of the production system with regard to the material creation and
other material flows.
The calculation of the required number of sites storage in production
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Simulation and models creation
The simulation should as first verify intended organizational and the
measures control and should eliminate the incorrect decision, which it could
lead to the problems in the company. Furthermore is possible:
• Production increase
• Position abate (worker, machine)
• Reduce of worker numbers
• Risks decrease to go back on terms of contract completion
• The ensure faster to start-up of new production
• The ensure faster to
start-up of the new transport system.
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M a c h i n i n g Te c h n o l o g i e s
I. Machining and diagnosis of complex shape objects
Universal
Micro-Tool
Grinder
Rapid prototyping
machine - metals
Multi-task
turning center
Milling machine for
machining of very hard
non-metallic materials
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M a c h i n i n g Te c h n o l o g i e s
Partners
ABF a.s. Praha – mediální partner, veletrh For Industry
AXA CNC stroje s.r.o. Hořovice – výrobce obráběcích strojů
SHM s.r.o. Šumperk – depozice vrstev na nástroje
GÜHRING s.r.o. Plzeň-Sulkov – výrobce nástrojů pro obrábění
GTW Bearings s.r.o. – výrobce kompozicových ložisek
ISCAR ČR s.r.o. - distributor nástrojů pro obrábění
SANDVIK CZ s.r.o. – distributor nástrojů pro obrábění
HOFMEISTER s.r.o. – výrobce nástrojů pro obrábění
PILSEN TOOLS s.r.o. – výrobce nástrojů a nářadí
Saint-Gobain Sekurit ČR s.r.o. Hořovice – Výrobce autoskel
Škoda Power, a.s. Plzeň – výroba energetických zařízení
SolidVision, s.r.o. Brno – CAD/CAM/CAE/PDM systémy
Strojírna TYC s.r.o. Mýto – výrobce obráběcích strojů
SVAZ STROJÍRENSKÉ TECHNOLOGIE – mediální a odborná podpora
ČESKÁ SPOLEČNOST PRO JAKOST, o.s. – odborná podpora
ČESKÁ SPOLEČNOST STROJÍRENSKÉ TECHNOLOGIE – mediální a odborná podpora
MM průmyslové spektrum – vydavatel odborných časopisů
Technometra a.s. Praha – výroba součástí pro letecký průmysl
HAM-FINAL s.r.o. – výrobce nástrojů pro obrábění
Pramet Šumperk a.s. – výrobce nástrojů pro obrábění
Asseco Solutions a.s. – informační systémy
Robert BOSCH, a.s. ČB – výrobce systémů převážně v segmentu Automotive
ASTRO KOVO Plzeň – výrobce dílů převážně rotačního charakteru
Innomia, a.s. Jaroměř – 3D tisk plastů a kovů
CompoTech, s.r.o. Sušice – Výrobce kompozitních materiálů a výrobků
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Thank you for your attenti on!