1. INTElligent FIXtures for the manufacturing of low rigidity components Grant agreement no: 609306 GENERAL PRESENTATION This project is part of the I4MS initiative Kick-off meeting 15-16/06/2013

2. PROJECT DATA Partners: 22 Starting date: July 2013 Ending date: June 2016 Duration: 3 years/36 month Budget: 9.639.391 EC contribution: 7.499.998 (including the OPENCALL) OPENCALL: EC contribution: 1.500.000 Tentative call date: february/march 2014 Minimum number of new experiments: 3

3. INTRODUCTION Manufacturing industry needs: Precise machining of medium and big size parts (aeronautic, space or energy sectors) Increase the performance of the machining processes Conventional functions of fixtures: securely hold and accurately locate the workpiece INTEFIX Use of intelligent fixture systems, allowing the monitoring, control and adaptation of the process to obtain suitable results according to precision, quality and cost requirements Additional functions of INTEFIX fixtures: Reduce the impact of the deformations, vibrations and distortions in the workpiece during processing CONCEPTS: Mechatronic/Adaptronic systems based on sensors, actuators, control algorithms, simulation tools Tuneable behaviour of the Machining system (machine-fixture-workpiece) Use of modular elements Applicable to other processes such as welding repair, assembly, etc.

4. CHALLENGES OF INTELLIGENT FIXTURES The development of adaptive, efficient and intelligent fixtures faces different challenges: To provide high accuracy and repeatability, being the fixtures tolerances 20% to 50% of the workpieces tolerances. To be safe and reliable, minimizing clamping variability and prevent clamping errors that lead to scraps and rejected parts. To maintain the workpieces references and provide a high degree of repeatability despite the use of active elements (displacements). To be automatic instead of manual, in order to reduce the process time and errors. To be cost-effective, taking into account the higher cost associated to sensors, actuators and electronics. To reduce the set-up time for a new configuration/component. To be modular (reconfiguration, disassembling and reusing). To be robust, durable and resistant to withstand the severe conditions during machining process (chips, cutting fluids, vibrations...). To be able to identify the process limitations (vibrations, deflections...) and to adapt the behavior.

5. ADVANTAGES OF INTELLIGENT FIXTURES The possibility of use an active intelligent modular fixture allows: Change the fixture behavior (static and dynamic) by modifying the position, clamping force, modal frequencies, damping ratio or stiffness of the whole system (machine-fixture-workpiece). Mitigation or avoidance of process static problems (position, deflections, distortions...) and dynamic problems (chatter, forced vibrations) during machining. Dynamic control of the fixture based on sensors (laser, piezoelectric, MEMS, FBG sensors...) and actuators (hydraulic, pneumatic, mechanical...). Increased process performance (Precision and quality, MRR, tool life, ecoefficiency). Increased process control (monitoring, mechatronic and adaptronic systems...). Reduction of manufacturing time and scrap. Reuse of fixture components and easy adaptation to new workpiece geometry (using zero point clamping, modular elements) .

6. MAIN OBJECTIVE The INTEFIX project aims to establish fixture design methodologies taking advantage of the available state of the art software and hardware tools (sensors, actuators, CAD/CAM/CAE, CNC, PLC, process simulation tools,...) combined with ad-hoc ICT tools (control algorithms, simulation tools...) to control and adapt the behaviour of the fixture, resulting in the development of intelligent fixtures. These methodologies will be based on the use of modular elements to obtain highly configurable, fast, accurate and durable fixture systems. ACTUATORS SENSORS PROCESS, MACHINE TOOL and FIXTURE ACTUATION MONITORING INTEFIX Experiments State of the art systems Adaptive fixture Modular elements Methodology Integration Intelligent fixtures QUALITY, PRECISION, PERFORMANCE, EFFICIENCY, SUSTAINABILITY The INTEFIX project development is based in three pillars: Monitoring / Acting / Control Fixture behaviour

7. SPECIFIC OBJECTIVES (1/2) The project aims at the installation of intelligent fixtures and the development of assessment experiments to probe their suitability in improving machining processes. Reduction of 50% in the development time of fixtures for complex components. Reduction of 50% workpiece setup time and increasing the machine operator safety. Development of intelligent and adaptable fixtures able to respond against undesirable forces, vibrations and displacements coming from material removal process related changes. Application of adaptronic concepts to the development of fixtures and fixture elements for machining operations. Application of state of the art sensors (laser, piezoelectric), conventional actuators (Pneumatic, hydraulic) and alternative actuators (magneto-rheological, piezoelectric actuators). Use of advanced materials (composite materials) to improve the fixture behaviour (Damping), weight and cost. Development of monitoring and control strategies and algorithms to obtain a suitable and fast response of the intelligent fixture. Integration of the fixture control system in the CNC or PLC to obtain the monitoring information available (machine internal signals of power, torque, axes positions...) and to modify the cutting conditions. Development of a solution for the modularization and standardization of the sensing and acting modules, allowing accurate and repeatable positioning of the work piece (zero-point clamping based systems).

8. SPECIFIC OBJECTIVES (2/2) Improvement of 15% of machining performance due to the avoidance of vibrations and chatter imposed limitations. Improved reliability of the machining operation due to the active control of vibrations, deflections and distortions. Leading to a reduction of rejections of 70-90%. In depth knowledge about the performance of different state of the art sensors and actuators for the improvement of machining processes. Adaption of state of the art simulation tools (chatter, forces, modes, deformations...) to predict the behaviour of the fixture subjected to the process loads. Two alternatives for the use of the intelligent fixtures: a) Real time fixture adaption from the process monitoring data, or b) Predefined fixture adaptation from the pre-process simulation. Definition of suitable and adapted CNC tool path attending to the process conditions and workpiece-fixture behaviour. Integration of the INTEFIX systems for their validation in selected machining applications.

9. STRUCTURE OF THE PROJECT The structure of the project is based in a series of CASE STUDIES for which suitable solutions will be developed combining sensors, actuators, machining technology and ICT technologies. The case studies are divided in three application scenarios: SCENARIO 1: VIBRATION. Workpieces with problems of vibrations during machining. SCENARIO 2: DEFORMATION. Workpieces with problems of deflections/distortions during machining. SCENARIO 3: POSITIONING. Workpieces with problems of reference setting. SCENARIO 2 DEFORMATIONS SCENARIO 3 POSITIONING WP 7 CS 2.1 WP 11 CS 3.1 WP 6 CS 1.2 WP 13 CS 0.1 CASE STUDY n Coordinating partner Technology supplyers RTD performers End-user WP 9 CS 2.3 WP 13 CS 3.2 WP 10 CS 2.4 WP14 CS 0.2 WP15 CS 0.3 WP 8 CS 2.2 CASE STUDY n Coordinating partner CASE STUDY n CASE STUDY n Coordinating partner Coordinating partner Technology supplyers RTD performers End-user Technology supplyers RTD performers End-user WP4: INTEFIX methodology development Technology supplyers RTD performers End-user RESULTS WORK PACKPAGES WP1 Management Case studies from OPEN CALL SCENARIO 1 VIBRATIONS WP 5 CS 1.1 OPEN CALL WP2 Training, dissemination and exploitation WP3: Specifications CASE STUDY n Coordinating partner Technology supplyers RTD performers End-user

10. SCENARIO 1: VIBRATIONS Case Study 1.1. Identification and active damping of critical workpiece vibrations in milling of thin-walled impellers/blisks. The objective is to limit the vibrations in components with blade features in order to obtain a more precise process with suitable surface finishing. This objective will be achieved by the introduction of sensors and active elements commanded by control algorithms feed by advanced process modelling software tools. Case Study 1.2. Turning of low pressure turbine casing. The objective is the improvement of the turning performance by using sensors to detect the presence of undesired vibrations and actuators to modify the fixture-workpiece dynamic behaviour.

11. SCENARIO 2: DEFORMATIONS (1/2) Case Study 2.1. Detection and compensation of workpiece distortions during machining of slender and thin-walled aerospace parts. The objective is the automated correction of workpiece distortions due to the material removal and residual stress state change, and the modification of the fixture configuration (force and position) to minimize the deformation related to the clamping process. Case Study 2.2. Clamping of thin-walled curved workpieces. The objective is the minimization of deformations of the workpiece during the machining due to changeable stiffness by simultaneous measurement and correction of errors caused by the cutting process and fixturing elements.

12. SCENARIO 2: DEFORMATIONS (2/2) Case Study 2.3. Distortions in aeronautical structural parts. The objective is counteract the distortions of workpieces with huge material removal and residual stress relieving using the fixture elements to control the position and the clamping force. Case Study 2.4. Machining of aircraft turbine support structures. The objective is control the deformation of complex geometry welded structure in the subsequent machining operations. It also covers the introduction of damping to avoid the vibrations associated to the modified clamping conditions associated to the distortions.

13. SCENARIO 3: POSITIONING Case Study 3.1. Fixture system for workpiece adjustment and clamping with/without its predeformation. The objective is the control of the positioning of the workpiece during the set-up process maintaining the relative references, and taking into account the deformations associated to the own weight. Case Study 3.2. Semiautomatic tool reference for application on large parts. The objective is the introduction of fixtures able to measure and displace the workpiece to optimize its position in order to avoid problems related to lack of base material in certain zones.

14. More information: www.intefix.eu www.i4ms.eu Contact: Oscar Gonzalo (oscar.gonzalo@tekniker.es)