2014 10-15-workshop-machinenauwkeurigheid-sirris

'Ontdek machinenauwkeurigheid in de praktijk!
15/10/2014

© sirris 2007 | www.sirris.be | info@sirris.be | 2
Agenda
13h00 Welcome & agenda
13h10 Introduction Etalon
LaserTRACER & LaserTRACER-MT
15h15 Sirris / Advanced Manufacturing
15h45 Break
16h00 Demo of Lasertracer-MT at Fehlmann
Versa P825
Guided tour at Sirris Precision & Smart
Factory Lab
17h00 Networking & drink
15.10.14

Agenda
15h45 Break
Versa P825
Factory Lab
15.10.14

Sirris “Driving industry by technology”
Sirris – Collective center of the Belgian technology industry
krist.mielnik@sirris.be
© sirris | www.sirris.be | info@sirris.be | 8

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
FACTORIES OF FUTURE
WORLD CLASS TECHNOLOGIES
ADDITIVE MANUFACTURING
METALS
COMPOSITES
PLASTICS & HYBRIDS
COATINGS
NANOMATERIALS
ECO-MECHATRONICS
SENSORIZED FUTURE
MODEL BASED DESIGN
SOFTWARE ENGINEERING
CLOUD COMPUTING
DATA INNOVATION

High-tech infrastructure & 160 employees
11
on 7 sites close to industry
© sirris | www.sirris.be | info@sirris.be |

High-tech infrastructure
Coating Deposition Additive Manufacturing Micro Precision
Microfabrication Robotics & Cobots Climatic Test Chamber
© sirris | www.sirris.be | info@sirris.be | 15.10.14 12

Research, develop and test your new
applications on an industrial scale
13
The Sirris Application Labs

Inspiration for technology and innovation
14
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
15
2500 companies
2485 SMEs (250 employees)
115 big companies (250 employees)

International network

Advanced Manufacturing
FACTORIES OF FUTURE
WORLD CLASS TECHNOLOGIES
ADDITIVE MANUFACTURING
METALS
COMPOSITES
PLASTICS HYBRIDS
COATINGS
NANOMATERIALS
ECO-MECHATRONICS
SENSORIZED FUTURE
MODEL BASED DESIGN
SOFTWARE ENGINEERING
CLOUD COMPUTING
DATA INNOVATION

Precision Manufacturing

Precision manufacturing
for new and better products
19
“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.”

Infrastructure

Research topics
1. Fast prototyping of precision parts
2. Extreme low surface roughnesses
3. Finishing complex shaped parts in difficult
materials
4. Surface details on large parts
5. Finishing brittle parts
6. Controlling deformations (tensions)
7. Garantee the precision on series

© sirris 2007 | www.sirris.be | info@sirris.be | 15.10.14 22
Machine accuracy (topic 7)

Advantages Possible to measure 3D tool center point for a random trajectory; this is a
Machine accuracy - Direct
Ball bar
Commercial
supplier
Renishaw
www.renishaw.com
Axes that can
be measured
Linear axes
Measuring
trajectory
KGM
1) Circular trajectory (movement of linear axes); radius is limited by
Commercial
Heidenhain
length of supplier
ball bar (www.extentable to heidenhain.de
max. radius = 600mm)
2) 3 planes (XY, YZ, ZX)
Axes that can
be measured
Linear axes
Advantages 1) Easy, well-known and quick test
Laser tracer
2) All measured parameters are taken in one measurement
Measuring
trajectory
Commercial
supplier
Etalon
www.etalon-ag.com
Random 2D-trajectory in a flat plane (measuring zone is limited by dimensions of
grid size)
Disadvantages 1) Error diagnosis requires experience
Advantages 1) Possible to measure a random trajectory in a 2D-surface.
2) Not possible to automate measurements
Machine-errors
that can
be measured
2) Very suitable for measuring dynamical errors on non-circular trajectories (e.g.
square) to finetune servo parameters afterwards
Axes that can
be measured
Linear axes
Rotary axes
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
Disadvantages 1) Grid plate is fragile
2) Experience is necessary for error diagnosis
3) More expensive than ballbar system
Machine-errors
that can
Measuring
trajectory
Random 3D-trajectory in space
1) Measuring zone is limited by length of ball bar device (local errors);
be extendable to measured
600mm
2) Dimensions (except diameter value of executed test)
3) Errors related to rotary axes
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
Machine-errors
that
cannot be
measured
unique feature
Disadvantages 1) Time-consuming
1) Cannot be used for 3D-measurement of volumetric accuracy
2) Cannot be used for errors of rotary axes
2) System is not the cheapest among the others
Machine-errors
that can
be measured
All static errors of linear and rotary axes. Etalon software gives for each
linear axis geometric errors (positioning error, straightness error,
perpendicularity errors, …)
Machine-errors
that
cannot be
measured
Dynamic errors
R-test
Commercial
supplier
IBS Precision
www.ibspe.com
Axes that can
be measured
Rotary axes
Measuring
trajectory
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
Machine-errors
that can
be measured
1) Positioning and orientation errors of rotary axes
2) Motion errors of rotary axes
Machine-errors
that
cannot be
measured
Errors of linear axes

Machine accuracy - Indirect

Machining of ceramics (topic 5)
Machining of ceramics
in hardened state
- State of art of
current machining
technologies?
- Problem: how to
select the best one
for your application?

15.10.14
Machining of ceramics
Demonstrator
ZrO2-TiN 60/40 disks
of Ø 40mm and height
UAG
ELID-Grinding
Die sinking EDM
Micro-EDM
Micromilling

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
Gear-making technologies
•Disc milling (moduul frezen)
•Gear shapers (afwikkel frezen)
•Gear hobbing
•Finishing (grinding)
Prototyping?
Dedicated tools!
Case gear (topic 1)

Technologies
Precision milling
Wire EDM
SLM

Mirror milling (topic 2)
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

Smart Production

Automated Loading Human Robot Interaction Measuring in production
Incremental Forming Sheet Metal Cell
Smart production
Infrastructure

Smart production
Baxter, the collaborative robot (cobot)
Human Robot Interaction
New generation
collaborative robot
(Cobot)
Safe human-robot
cooperation
Easy to use

34
Smart production
Baxter, the collaborative robot (cobot)

35
Smart production
Measuring in production
Measuring in production

36
Smart production
Signature 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 production
ISF

Services
Shared capacity
Prototypes
Process optimization
Case studies
Participation of companies in research projects
(user groups)

Guided tour at Sirris Precision Smart
Factory Lab
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
http://blog.sirris.be http//techniline.sirris.be
#sirris - @sirris_be
http://www.linkedin.com/company/sirris

2014 10-15-workshop-machinenauwkeurigheid-sirris

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