2014 10-15-workshop-machinenauwkeurigheid-sirris

'Ontdek machinenauwkeurigheid in de praktijk!

15/10/2014

© sirris 2007 | www.sirris.be | [email protected] | 2

Agenda

13h00 Welcome & agenda

13h10 Introduction Etalon

LaserTRACER & LaserTRACER-MT

15h15 Sirris / Advanced Manufacturing

15h45 Break

16h00 Demo of Lasertracer-MT at FehlmannVersa P825

Guided tour at Sirris Precision & Smart Factory Lab

17h00 Networking & drink

15.10.14


Agenda





15h45 Break




15.10.14

Sirris “Driving industry by technology”

[email protected]

8© sirris | www.sirris.be | [email protected] |

Sirris – Collective center of the Belgian technology industry

Driving industry by technology

“We help large and smaller players

in Belgian technology industry

make the right technological choices and achieve sustainable

economic growth.”


5 domains of technology


METALS

COMPOSITES

PLASTICS & HYBRIDS

COATINGS

NANOMATERIALS

ECO-MECHATRONICS

SENSORIZED FUTURE

MODEL BASED DESIGN

FACTORIES OF FUTURE

WORLD CLASS TECHNOLOGIES

ADDITIVE MANUFACTURING

SOFTWARE ENGINEERING

CLOUD COMPUTING

DATA INNOVATION

High-tech infrastructure & 160 employees

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on 7 sites close to industry

© sirris | www.sirris.be | [email protected] |

High-tech infrastructure

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Coating Deposition Additive Manufacturing Micro Precision

Microfabrication Robotics & Cobots Climatic Test Chamber

Research, develop and test your new applications on an industrial scale

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The Sirris Application Labs


Inspiration for technology and innovation

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� Stay informed?

Follow our blog! blog.sirris.be

� Find out more?

Consult our digital technology library, Techniline! techniline.sirris.be

� Invest in knowledge?

Check out our calendar of upcoming events! www.sirris.be/agenda


Members of Sirris

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2485 SMEs (<250 employees)

2500 companies

115 big companies (>250 employees)


International network


Advanced Manufacturing


METALS

COMPOSITES

PLASTICS & HYBRIDS

COATINGS

NANOMATERIALS

ECO-MECHATRONICS

SENSORIZED FUTURE

MODEL BASED DESIGN

FACTORIES OF FUTURE

WORLD CLASS TECHNOLOGIES

ADDITIVE MANUFACTURING

SOFTWARE ENGINEERING

CLOUD COMPUTING

DATA INNOVATION

Precision Manufacturing


Precision manufacturingfor new and better products

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“Over a period of 5 years

the product tolerances will decrease

by a factor 3 to 4

but the costs of production

will have to remain at the current level.”


Precision manufacturingInfrastructure


15.10.14 21© sirris | www.sirris.be | [email protected] |

1. Fast prototyping of precision parts

2. Extreme low surface roughnesses

3. Finishing complex shaped parts in difficultmaterials

4. Surface details on large parts

5. Finishing brittle parts

6. Controlling deformations (tensions)

7. Garantee the precision on series

Precision manufacturingResearch topics

© sirris 2007 | www.sirris.be | [email protected] | 2215.10.14

Precision manufacturingMachine accuracy (topic 7)


Precision manufacturingMachine accuracy - Direct

Ball bar

Commercial supplier

Renishaw www.renishaw.com

Axes that can be measured

Linear axes

Measuring trajectory

1) Circular trajectory (movement of linear axes); radius is limited by length of ball bar (extentable to max. radius = 600mm) 2) 3 planes (XY, YZ, ZX)

Advantages 1) Easy, well-known and quick test 2) All measured parameters are taken in one measurement

Disadvantages 1) Error diagnosis requires experience 2) Not possible to automate measurements

Machine-errors that can be measured

1) Statical errors of linear axes, like squareness 2) Dynamical errors (quadrant glitch, backlash, stick slip) (ISO 230-4) 3) Volumetric tests (measuring in 3 planes) 4) Diameter value of executed test

Machine-errors that cannot be measured

1) Measuring zone is limited by length of ball bar device (local errors); extendable to 600mm 2) Dimensions (except diameter value of executed test) 3) Errors related to rotary axes

KGM

Commercial supplier

Heidenhain www.heidenhain.de


Linear axes


Random 2D-trajectory in a flat plane (measuring zone is limited by dimensions of grid size)

Advantages 1) Possible to measure a random trajectory in a 2D-surface. 2) Very suitable for measuring dynamical errors on non-circular trajectories (e.g. square) to finetune servo parameters afterwards

Disadvantages 1) Grid plate is fragile 2) Experience is necessary for error diagnosis 3) More expensive than ballbar system


1) Depends on the trajectory that has been followed 2) All static errors of 2 linear axes can be measured (positioning error, straightness error, angular errors, perpendicularity errors) 3) Dynamic contour errors can be evaluated


1) Cannot be used for 3D-measurement of volumetric accuracy 2) Cannot be used for errors of rotary axes

Laser tracer

Commercial supplier

Etalon www.etalon-ag.com


Linear axes Rotary axes


Random 3D-trajectory in space

Advantages Possible to measure 3D tool center point for a random trajectory; this is a unique feature

Disadvantages 1) Time-consuming 2) System is not the cheapest among the others


All static errors of linear and rotary axes. Etalon software gives for each linear axis geometric errors (positioning error, straightness error, perpendicularity errors, …)


Dynamic errors

R-test

Commercial supplier

IBS Precision www.ibspe.com


Rotary axes


Circular trajectory with synchronous movement of both linear and rotary axes

Advantages 1) 3D-trajectory of sphere can be measured; more information can be gathered in shorter time (compared with ball bar) 2) Measurements can be automated

Disadvantages 1) Device is more fragile than ball bar system 2) Errors of linear axes should be small during R-test (difficult to separate errors coming from linear and rotary axes) 3) More expensive than ball bar system


1) Positioning and orientation errors of rotary axes 2) Motion errors of rotary axes


Errors of linear axes


Precision manufacturingMachine accuracy - Indirect

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Precision manufacturingMachining of ceramics (topic 5)

Machining of ceramicsin hardened state

- State of art of current machiningtechnologies?- Problem: how toselect the best onefor your application?

15.10.14

Demonstrator

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ZrO2-TiN 60/40 disks of Ø 40mm and height

UAG

ELID-Grinding

Die sinking EDM

Micro-EDM

Micromilling

Precision manufacturingMachining of ceramics

15.10.14

Precision gear

• (Hardened) Steel (200-400 HV)

• Dimensional tolerances up to +/- 7 �m

• Roughness: <0.8 �m Ra for milled area

• Diameter: 82,8 mm

• Depth: 41,5 mm

© sirris | www.sirris.be | [email protected] | 28

Gear-making technologies•Disc milling (moduul frezen)•Gear shapers (afwikkel frezen)•Gear hobbing•Finishing (grinding)

Prototyping?Dedicated tools!

Precision manufacturingCase gear (topic 1)

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Precision manufacturingTechnologies

Precision milling

Wire EDM

SLM


Code Ra (µm) Rz (µm) Ra (µm) Rz (µm)

brown 0,021 0,15 0,017 0,14

0,025 0,14 0,013 0,12

0,022 0,17 0,014 0,17

blue 0,094 0,58 0,056 0,31

0,082 0,46 0,05 0,29

0,085 0,51 0,048 0,26

grey 0,099 0,07 0,43

0,097 0,73 (0,303) (1,72)

0,089 0,59 0,074 0,47

red 0,106 0,73 0,048 0,37

0,052 0,39 0,051 0,33

0,078 0,56 0,045 0,3

PCD

parallel milling direction perpendicular on milling direction

MCD

MCD

PCD

Precision manufacturingMirror milling (topic 2)

Smart Production



Automated Loading Human Robot Interaction Measuring in production

Incremental Forming Sheet Metal Cell

Smart productionInfrastructure


Human Robot Interaction

Smart productionBaxter, the collaborative robot (cobot)

New generation collaborative robot (Cobot)

Safe human-robot cooperation

Easy to use

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Smart productionBaxter, the collaborative robot (cobot)

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Smart productionMeasuring in production

Measuring in production

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Smart productionSignature analysis

� Control of an automated production process (cutting process)

� Autonomous control of cutting process

� Based on an acoustic signal

� Comparing with a reference signal (= good process)

� Alarm if there is a problem (tool wear, tool breakage)

� Incremental sheetmetal forming

� Innovative and flexibel processing technique

� Big variety of geometries possible

� No need for expensive tooling


Smart productionISF


Services

� Shared capacity

� Prototypes

� Process optimization

� Case studies

� Participation of companies in research projects(user groups)



� 5-axis precision milling machine Fehlmann P825 Versa

� Smart pick glasses

� Automatic measuring cell Kogame-Safety Eye

� Signature analysis

� Baxter robot

15.10.14

http://www.sirris.be

#sirris - @sirris_be

http://www.linkedin.com/company/sirris

http://blog.sirris.be & http//techniline.sirris.be


2014 10-15-workshop-machinenauwkeurigheid-sirris

Technology