Innovation in manufacturing processes for metalworking production

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The European Association of the Machine Tool Industries
Innovation in manufacturing
processes for metalworking
production facilities
Industrial Technologies 2012
Mr. Luigi Galdabini
" where manufacturing begins"
Agenda
1.
2.
3.
4.
5.
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
Industrial Technologies conference June 2012
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
Industrial Technologies conference June 2012
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
Industrial Technologies conference June 2012
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
Industrial Technologies conference June 2012
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
Industrial Technologies conference June 2012
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
Industrial Technologies conference June 2012
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
Industrial Technologies conference June 2012
R&D efforts for sustainable manufacturing
Coordinator: Tecnalia
Coordinator: Fiat Research Center
Industrial Technologies conference June 2012
CECIMO R&D priorities
The R&D priorities :
Standby
• 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
Machine Envirement
Industrial Technologies conference June 2012
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
© 2012 Fastems
Industrial Technologies conference June 2012
thank you
questions
Filip Geerts, Director General
CECIMO – The European Association of the Machine Tool Industries
Avenue Louise 66 | 1050 Brussels | Belgium
Tel.: 00 32 (0)2 502 70 90
Email: [email protected]
Website: www.cecimo.eu
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