fichas smart connected machines - Basque industry...Investigation into new grinding wheel...

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SMART ANDCONNECTED

MACHINES

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EKONOMIAREN GARAPENETA AZPIEGITURA SAILA

DEPARTAMENTO DE DESARROLLOECONîMICO E INFRAESTRUCTURAS

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Cell for research on large size parts grinding

Cell for research and development acrivities in high-performance grinding processes for medium-large dimension pieces with high added value in sectors such as aeronautics, railways and energy. Composed by a horizontal cylindrical grinding machine equipped with a double rotating head, a multidiameter measuring system with high flexibility and precision. A second machine in the cell is a vertical multitasking cylindrical grinding machine, with capacity for hard turning, cylindrical grinding of inner and outer diameters and face grinding, as well as an in-process measurement system. The cell is completed with a mobile column multitasking machine with capacities for milling, turning and grinding, equipped with a robotic magazine with up to 150 tools.

The cell is completely monitored for the measurement of vibrations, forces, temperatures, in addition to the working parameters. This monitoring data

are transferred to the cloud platform from which the monitoring parameters are processed and analyzed, and is complemented by simulation models of the behavior of the three units that compose it. The operation of the three units is carried out through a specific proprietary HMI for grinding.

The cell is also equipped with systems for non-destructive inspection (NDT) through ultrasonic, eddy current and active thermography technologies. It has the ability to design specific sensors for applications and parts of interest, so that in addition to standard verification of the results of the processes studied and the rectified parts, customized solutions can be developed and tested.

The three units are connected to each other in addition to connecting to IDE.005 assets.

THE MOST OUTSTANDING EQUIPMENT AND COMPONENTS

• DANOBAT HG72-3000 grinding machine

Medium to large size cylindrical grinding machines, equipped with double wheel tilting headset and a multidiemeter integrated measuring system.

• DANOBAT VG800 vertical grinding machine

Multitasking Cylindrical vertical grinding machine, with capacity for hard turning, cylindrical ID - OD and face grinding, in addition to an in-process measurement system



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SERVICES OFFERED BY THE ASSET

Research on new grinding processes and special grinding cycles

Design and testing of new special grinding cycles for parts of high value and complexity: new materials, process conditions, lubrication. Testing of special grinding cycles: non round shapes, curvics, thread elimination, smooth cycles

Research on the behavior of new advanced components: grinding wheels, cooling systems, measurement systems, special heads, dressing systems

Testing, evaluation and validation of components of grinding machines: new wheel compositions (superabrasive, carbon fi ber bodies, conventional high speed wheels), cooling systems and elements, machine-integrated measurement and inspection systems, dressing systems.

Tests on special production conditions for particular parts

Defi nition and design of new cycles that provide productive advantages to parts of special complexity

Training and updating of specialists

Specialized training courses for new professionals and for updating professionals to new technologies.

ENTITY THAT MANAGES THE ASSET

IK4-IDEKOContact Person:Rafa [email protected]

• SORALUCE FMT4000 multitasking machine

Travelling column multitasking machine with capacities for milling, turning and grinding, equipped with a robotized tool magazine of 150 tools. The machine is also equipped with the DAS+ active damper for maximum cutting capability and adaptive process.

• DoGrind

DoGrind programming software specifi c for general purpose and also special grinding cycles (shapes, curvics).

• Non Destructive Testing

Equipment for verifi cation of surface integrity, thermal damage and residual stresses throughUltrasound, Eddy Current and Active Thermography



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Cell for research on high precision parts

Cell for research and development of high precision grinding processes in small dimension parts from industrial sectors with high dimensional and surface quality requirements, in sectors such as automotive, optics, medicine, energy, aeronautics and aerospace.

The cell is composed by an horizontal cylindrical grinding machine equipped with a double rotating head, with the possibility of incorporating conventional and superabrasive wheels, which work at high cutting speed. The versatility of the machine allows to perform processes of plongeé, grinding of faces, and peel grinding.

A second equipment of the cell is a cylindrical grinding machine for grinding external, internal diamters and face grinding, with high precision and stability. The cell is completed with a centerless grinding machine of high grinding capacity that allows work in plongeé and throughfeed, for an extensive variety of parts geometries.

The three machines, connected to each other, can work independently or in combination, having

a specific software interface (HMI), which allows intuitive and simple programming of the different cycles mentioned above, in addition to special cycles such as grinding of shapes (cams, eccentric).

The cell is completely monitored for the measurement of vibrations, forces, temperatures, in addition to the working parameters. This monitoring is transferred to the cloud platform from which the monitoring parameters are processed and analyzed, and is complemented by simulation models of the behavior of the three units that compose it.

The cell also has systems for non-destructive inspection (NDT) through ultrasonic, eddy current and active thermography. It has the ability to design specific sensors for applications and parts of interest, so that in addition to standard verification of the results of the processes studied and the rectified parts, customized solutions can be developed and tested.

The three units are connected to each other in addition to connecting to IDE.004 assets.


• DANOBAT LG 1200 cylindrical grinding machine

Horizontal cylindrical grinding machine equipped with a double grinding wheel rotating head, with the possibility of incorporating conventional and superabrasive grinding wheels. The versatility of the machine allows to perform processes such as plongeé, grinding of faces, and peel grinding.

• Danobat Overbeck IRD grinding machine

Cylindrical grinding machine for high precision grinding OD, ID and faces, with high precision and stability



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Research on new grinding processes and special grinding cycles

Design and testing of new special grinding cycles for parts of high value and complexity: new materials, process conditions, lubrication. Testing of special grinding cycles: non round shapes, curvics, thread elimination, smooth cycles, hard materials, ceramics

Research on the behavior of new advanced components: grinding wheels, cooling systems, measurement systems, special heads, dressing systems

Testing, evaluation and validation of components of grinding machines: new wheel compositions (superabrasive, carbon fi ber bodies, conventional high speed wheels), cooling systems and elements, machine-integrated measurement and inspection systems, dressing systems.

Tests on special production conditions for particular parts

Defi nition and design of new cycles that provide productive advantages to parts of special complexity




IK4-IDEKOContact Person:Rafa [email protected]

• Danobat Estarta 650 centerless grinding machine

Centerless grinding machine for working in plongeé and throughfeed conditions, for an extensive variety of geometries of pieces.

• V3 proprietary algorithms for optimising grinding cycles

Special programming algorithms that allow optimising the total grinding cycle by optimising the key parameters: precision, cycle time, energy consumption.

• Non Destructive Testing

Equipment for verifi cation of surface integrity, thermal damage and residual stresses through Ultrasound, Eddy Current and Active Thermography



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DANOBAT LG-600-B2 high-precision grinding machine

The DANOBAT LG-600-B2 is a high-precision grinding machine for external and internal grinding operations. Its natural granite bed and linear motors provide the necessary precision and thermal stability required for these demanding applications. Allows peripheral speeds of up to 140 m/s with superabrasives and 60 m/s with conventional abrasives.

As for the machine configuration, it has linear movements on the X-axis in radial direction and

axial movements on the Z-axis, driven by linear motors and controlled by encoders with the B-axis for wheel position setting.

It has a user-friendly conversational DOGRING software developed by DANOBAT for programming grinding operations, as well as an automatic wheel balancing system.


• Universal grinding machine DANOBAT LG-600-B2 with the coolant processing unit with filter belt and magnetic separator drum FILBER

Universal grinding machine DANOBAT LG-600-B2 with the coolant processing unit with filter belt and magnetic separator drum FILBER


Specific training aimed at company technicians

Set of training activities related to grinding technology aimed at company technicians through training for employment, with the aim of improving the competitive capabilities of technicians.

Search for optimum grinding parameters for industrial applications

Analysis of grinding processes and search for optimum parameters to improve process performance in specific industrial applications.



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IMH - Fundación para la Formación Técnica en Máquina-Herramienta/Makina Erreminten Hezkuntza Teknikorako Fundazioa Contact Person:Xabier Cearsolo [email protected]

Use of the asset as a test bench for the performance of experimental tests

Performance of experimental grinding and diamond dressing tests in order to obtain process data such as: process performance, comparative study of grinding wheels and diamonds in terms of performance, statistical process analysis, etc.



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Research unit in data analytics 4.0 for grinding

Research and development unit for advanced applications of data analytics 4.0 for the improvement of grinding applications. This unit is equipped with a high-performance Blohm Planomat grinding machine and a high-speed cylindrical Danobat (including contouring with a CBN wheel), fully sensorized for extensive data collection and efficiency analysis of grinding applications, including new generation grinding wheels, new lubrication and refrigeration strategies. The sensorization includes Kistler

dynamometers, various types of diamond dressing tools, data acquisition systems, power meters, latest generation systems for measuring in-process temperatures, wear measurement systems and data analytics systems (Machine Learning). The unit is complemented with numerical calculation software for the study and simulation of contact conditions (GranOO), commercial software (Ansys) and self-development for the analysis of in-process temperatures and applications developed in Python for Machine Learning and Deep Learning.


• Blohm Planomat Orbit Planing Grinder and High Speed Danobat Cylindrical Grinding Machine

Blohm Planomat Orbit Planing Grinder and High Speed Danobat Cylindrical Grinding Machine

• Complete and integrated sensor system

Complete and integrated sensor: dynamometer, power meter, acoustic emission, two-color pyrometer, acquisition system, etc.

• Free software for DEM contact analysis (GranOO)

• Commercial software (Ansys) and proprietary development (GrndTemps)

• Free software and proprietary development for data analytics 4.0 Anaconda, Python



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Research in machine data monitoring and analytics 4.0

Tests, training, and proposals to improve apps through data analytics (Machine Learning, Deep Learning)

Investigation into new grinding wheel formulations

Feasibility study, testing and analysis of grinding results using new application-oriented grout formulations.

Research into new ecological lubrication methods

Testing, training, and analysis of results in efficient and ecological lubrication systems for grinding.


UPV/EHU Contact Person:José Antonio Sánchez Galí[email protected]



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Research unit for superabrasive and multitasking machining

Research and development unit for advanced applications of super abrasive machining for aeronautical applications in a multitasking machine. Includes a 5-axis HERMLE Multitasking machining center that combines milling, turning, and grinding. It has a main spindle power of 80 Kw and a maximum working diameter of 1200 mm, along with a torque motor on the C axis. This machine is oriented towards the manufacture of integrated

blade rotors such as Impellers and Blisks. The unit is complemented by high-resolution Metrology and Inspection services (GE Digital Radiography X-CUBE model), necessary for the type of sectors for which this technology is intended. It has two coordinate measuring machines of Cartesian kinematics from the manufacturer Mitutoyo, one of which is for contact measurement and the other for non-contact measurement (includes laser raster).


• HERMLE Multitasking 5-axis machine that combines milling, turning, and grinding

• Digital X-ray. GE X-CUBE model

• Coordinate Measuring Machine MITUTOYO CRYSTA APEX C162012

• Coordinate Measuring Machine MITUTOYO CRYSTA APEX S 9106


Research in super abrasive machining

Testing, training, and improvement of super abrasive machining applications aimed at the aeronautical industry

Research in multitasking machining

Feasibility study, testing, and improvement of applications in multitasking machining



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Research into new high-speed super abrasive tools

Testing, training, and development of alternative manufacturing methods using super abrasive tools


UPV/EHU Contact Person:José Antonio Sánchez Galí[email protected]



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Optimizedworking conditions selection cell in grinding

Optimized working conditions selection cell for any grinding application. The design of the cell is based on a tangential grinding machine equipped with an open numerical control that allows the implementation of external applications, as well as the monitoring of the machine’s own sensors.

The cell is completed with several equipments that allow to measure essential aspects to be able to evaluate the result of the working conditions used in the grinding of a given application. In this way, the measurement of the following parameters such as cutting forces (torque plate), wear of the grinding wheel (laser device and a CCD camera), roughness (portable roughness tester) and surface hardness (portable hardness tester) are allowed.

The main problem in grinding is the increase of the temperature in the contact area between the part and the grinding wheel, which causes a high risk of thermal damage that affects the surface integrity of the piece. The cell is equipped with a termographic camera and a fiber optic device that measures the temperature generated during the process.

On the other hand, the cell has the equipment to measure surface defects on the piece. This equipment is located in the materials laboratory and is accredited by the ENAC to carry out this type of measure. There are different types of microscopy (optics and SEM), macroscopy and profilometry.


• Surface grinding machine GER SN 100/50

Surface grinding machine equipped with a CNC Fagor 8070. It has a total power of 22 kw and 1000x500 mm dimensions table.

• METODES softwate to optimal wheel selection

A software implemented in the grinding machine to evaluate the performance of abrasive wheels. It is able to avoid thermal damage in the piece according to the Malkin predictive model.

• Sensors for process monitoring: power, force, vibration, position, thermography, laser, surface roughness.

Group of sensors that allow to monitor the grinding process.



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Ensuring surface integrity

Defi nition of the process windows that ensure the surface integrity of the grinded part. Structural analysis of rectifi ed surfaces.

Study of the eff ect of the lubricant on the application.

Determination of the optimal lubrication system for a given application: type of lubricant, nozzle geometry, fl ow rate, pressure. Study of the eff ect of the lubrication system on the rectifi ed part.

Training

Specialized training courses for new professionals and updating professionals in the grinding process


Mondragón Goi Eskola Politeknikoa JMA SCoop Contact Person:Raul Fernandez [email protected]

• Equipment for measurement of superfi cial defects: microscopy, macroscopy, profi lometry.

Laboratory for the measurement of superfi cial defects accredited by the ENAC: microscopy, macroscopy, profi lometry.



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Systems for mechanical properties and microstructure determination by magnetic non-destructive measurements

Device to measure magnetic properties, which allows obtaining an indirect characterisation of mechanical properties or the microstructure of ferromagnetic parts.

Non-destructive testing device useful to detect production defects as variations in the surface hardness, residual stresses, hardened layer or grinding burns.

Self-developed magnetic properties measurement system that can work with commercial or customised sensors depending on the geometry and characteristics of the part to be tested. This system can be used for manual measurements or automatised measurements by means of a robot using our customised compliant systems. Mechanical properties values of the parts can be obtained by calibration and measurement of magnetic properties.


• System for determination of mechanical properties by calibration and direct measurement of magnetic properties on steels

Own development

• System for detection of grinding burns of parts– Sensors for gears, screw shafts, bearings, camshafts – Technology to develop specific sensors for several component geometries

Own development. Various sensors can be coupled to gears, spindle shafts, bearings, camshafts - technology for specific development that can be coupled to various component geometries.

• System for magnetic property measurements in steels – magnetic hysteresis cycles (from 0.1 to 80 Hz) – determination of magnetic induction (B) at several magnetic field (H) values.

Self-developed. System for measuring magnetic properties in steels, magnetic hysteresis cycles (from 0.1 to 80 Hz), determination of magnetic induction at different H magnetic field levels

• Eddy current portable device.

Eddy current portable device. GE Inspection Technologies – Vector 2d with several probes.



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Development of grinding burn detection systems (by Magnetic Barkahusen noise)

Design and development of new non-destructive systems (manual or automatic) to detect grinding burns by magnetic Barkhausen noise

Magnetic nondestructive systems to determine the thickness of the hardened layer (case depth) in surface‐hardened components

Design and development of new non-destructive systems (manual or automatic) that detect variations on the hardened layer (surface hardness and case depth) and control the heat treatment by measurement of magnetic properties

Magnetic non-destructive systems to estimate residual stresses along the depth

Nondestructive estimation of residual stresses by indirect magnetic properties. Characterization of surface residual stresses or residual stress depth-profiles.

Analysis of mechanical properties by indirect measurement of magnetic properties

Estimation of mechanical properties (hardness, yield stress, tensile strength) by indirect measurement of magnetic properties

Measurement of magnetic properties at several frequencies

Assessment of magnetic properties (magnetic hysteresis cycles: coercivity, remanence, hysteresis losses, magnetic induction (B) at several values of magnetic field (H)) to check if the desired steel fulfills required standards)


CEIT-IK4 Contact Person:Kizkitza [email protected]



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X-Ray Diffractometer (XRD)

X’Pert MRD diffractomer from PANalytical with Euler cradle. Ideal for measurement of residual stresses and crystallographic texture. Horizontal diffactometer with both Bragg-Brentano and parallel beam optics. Max. weight 500 g, max. height 24 mm. Two radiations available, Cu and

Cr. Possibility of thin films characterization by Grazing Incidence X-Ray Diffraction. Software HIGH SCORE for phase identification; STRESS and TEXTURE for residual stresses and texture analysis, respectively. Indispensable technique for analysis and characterization of a wide range of materials.


• X’Pert MRD diffractometer

X’Pert MRD diffractometer with Euler cradle, Cu radiation, Bragg-brentano optics, cross-slit collimator, programable receiving slit, Xe proportional detector, softwares Data Collector”, PC-STRESS and PC-TEXTURE

• Co and Cr X-ray tubes

Parallel beam optics (pollicapilar lens, parallel plate collimator, graphite flat monochromator). Small angle slits for Grazing Incidence X-Ray Diffraction.


Measurement of residual stresses

Measurement of superficial residual stresses due to machining, forming processes, thermal treatment, welding processes, additive manufacturing, thin film deposition etc. Measurement as a function of depth by material elimination with electrolytic polishing. Stress analysis usually with sen2psi method; measurement both in PSi and OMEGA mode.

Quantification of fraction of retained austenite in steels

Measurement of amount of retained austenite in hardened steels based on the integrated intensity of several austenite and ferrite diffraction peaks, according to ASTM E975.



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Phase identification and quantification by conventional and grazing incidence in different materials and thin films. Quantification of crystallite size and micro-stresses.

Identification of crystallographic phases present in a material and their quantification (Rietveld method) in both bulk (conventional incidence) and thin film (GIXRD) materials. Quantification of crystallite size and micro-stresses based on the width of the diffraction peaks.

Crystallographic texture

Measurement of the distribution of crystallographic orientations in bulk materials and thin films. Texture originates from forming processes of metallic materials, as well as after thin film deposition, in casting processes, etc.


CEIT-IK4 Contact Person:Carmen Garcí[email protected]



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Dual Beam FEG-SEM FIB

DualBeam QUANTA3DFEG equipment from FEI. It has a high-resolution scanning electron microscope (~1nm) and a Gallium ion cannon that allows the deposition and ablation of material. In addition, CEIT-iK4 has developed an image analysis software

that allows to solve the residual stresses from the images obtained from FEGSEM before and after FIB milling in a range of scales from 1 um to 800 um and 0.5 - 50 um depth.


• DualBeam QUANTA3DFEG

DualBeam QUANTA3DFEG equipment from FEI. It has a high-resolution scanning electron microscope (~1nm) and a Gallium ion cannon that allows the deposition and ablation of material.

• Digital Image Correlation software developed by CEIT-IK4 in MATLAB

CEIT-iK4 has developed an image analysis software that allows to solve the residual stresses from the images obtained from FEGSEM before and after FIB milling in a range of scales from 1 um to 800 um and 0.5 - 50 um depth.


Measurement of stress profiles in depth of machined surfaces

Measurement of the evolution of the residual stress tensor with depth in the range of 0.5-50 micron. More sensitive within this range that conventional hole drilling techniques

Measurement of the distribution of residual stresses along a machined surface

Distribution of residual stresses along a machined surface with micrometric resolution. No alternative method is currently available with this spatial resolution.



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Measurement of residual stress profiled across welding and HAZ

Distribution of residual stresses across a welded surface with micrometric resolution. Study of the profile of residual stresses across the Heat Affected Zone (HAZ).


CEIT-IK4 Contact Person:Jon [email protected]



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Laboratory of geometric and materials characterization

Grinding is usually the last machining operation and for this reason it is necessary to guarantee the geometric precision of the workpiece, as well as the absence of cracks, residual stresses, etc. that endanger the useful life of the workpiece in operation.

To ensure the accuracy of the workpiece can affect three factors:

Precision of the machine. Especially if the machine is large, geometric errors can be important. To solve them, IK4-Tekniker has calibration systems.

Measurement of the piece in process. With the use of external measuring systems, the desired tolerances can be achieved.

Finally, in the case of complex geometries, Ik4-Tekniker has means to verify and certify the

different dimensional properties of the pieces.

In relation to the possible microstructural changes generated by the grinding operation in the component, IK4 - TEKNIKER has a complete characterization laboratory and highly qualified personnel that will provide crucial information for the determination of the optimal process parameters that guarantee the integrity of the component: microstructural modification through metallographic characterization, compositional characterization in surface, depth and bulk, characterization of crystallographic phases and characterization of residual stresses. Completing the basic characterization, IK4 - TEKNIKER has different laboratories that allow characterizing the life behavior of the component once subjected to the machining operations experienced by it and, in particular, the grinding operation.


• Laser tracker measurement system

Dimensional measurement equipment with laser tracker

• Laser tracer measurement system

Dimensional measurement equipment

• CMM machine

High precision CMM machine



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Compensation of volumetric errors.

Once measured the volumetric errors can be compensated by means of the numerical control of the machine

Measurement of volumetric errors

Measurement by laser tracer or laser tracker of the volumetric errors of the machines

Geometric verifi cation of pieces

Dimensional verifi cation of the rectifi ed parts.

Microstructural characterization of components

Metallographic characterization, composition, crystalline phases and residual stresses

Life tests of components

Thermal degradation in diff erent atmospheres, simulated degradation, stress corrosion at high temperature and aqueous medium, EIS, galvanic corrosion, resistance to traction, compression and shear, etc.

Correlation studies of machining process parameters and component integrity (and life)

From the basic and advanced characterization (trials to life), it is possible to estimate the integrityof the component and its life


Specialized training courses for new professionals and for updating professionals to new technologies

• Rugosimeter, profi ler

Surface dimensions measurement machine

• Metallographic, compositional characterization equipment, crystalline phases and residual stresses. Teams characterization of behavior to component life.

Metallographic, compositional characterization equipment (XR-Fluorescence, GDOES, SEM-EDX), crystalline phases and residual stresses (X-ray diff raction equipment). Equipment for characterization of behavior to component life (corrosion and aging, mechanical properties, erosion and scratching ...)


FUNDACIÓN TEKNIKERContact Person:Javier Arzamendi [email protected]

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Laboratory for the integral characterization of fluids and materials

Laboratory for the integral characterization of fluids (oils, taladrin, water based emulsion) and grinding materials (grinding wheels, material to be ground). This characterization covers the evaluation of the physical-chemical and mechanical properties of fluids and materials, as well as their tribological

performance in use. These studies provide a background for the development of improvement strategies focused on the use of more efficient and long-term fluids and materials, whether new products or commercia


• Laboratory for the integrated characterization of physical, chemical and thermal properties of grinding fluids. (Viscosity, thermal conductivity, spectroscopy...)

Laboratory with all the equipment and instruments for the physical, chemical and thermal characterization of grinding fluids. This equipment allows for the determination of the properties of new fluids as they are in use, which allows the establishment of quality control strategies for these fluids, as well as the assessment of new developments.

• Laboratory for material characterization (mechanical and surface properties, corrosion resistance, microstructure, residual tensions,...)

Laboratory for the study of grinding materials. The available equipment allows an integral evaluation of the processed material through the analysis of the mechanical, surface and microstructural properties.

• Tribological testing laboratory (friction and wear) for fluid/material system evaluation

Laboratory for the study and characterization of the tribological system (fluid/material) through the study of superficial phenomena from a tribological point of view, including friction and wear.



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Development of new grinding fl uids

Design and characterization of new formulations based on the selective additivation of the fl uid. Selection of additive strategies and physical-chemical characterization of the fl uid

Replacement of conventional formulations in special grinding processes

Replacement of oil-based coolant by a cost-eff ective water-based formulation for grinding special materials

Eff ect of cooling on tribo-thermo-mechanical grinding behaviour

Tribological evaluation of the eff ect of the proposed new refrigerants. Material analysis and process paramet

Effi ciency and durability of grinding fl uids and grinding wheels

Evaluation of the friction and wear behaviour of fl uids and grinding wheels in grinding operations

Corrosive eff ect of grinding fl uids

Study of the impact of the use of grinding fl uids on the corrosive process of adjacent parts

Research for machining waste sludges recovery

Defi nition of recovery techniques and new uses for the sludge obtained during the machining process, transformation into new chemical precursors.

In-situ regeneration of the cooling fl uid

Defi nition and development of new fi ltration technologies for the regeneration of coolant and metal working fl uids

Training and updating of experts



FUNDACIÓN TEKNIKERContact Person:Javier Arzamendi [email protected]

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fichas smart connected machines - Basque industry...Investigation into new grinding wheel...

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