The document discusses new machining concepts and technologies for advanced metal cutting. It begins with an agenda that outlines topics such as MAG being a global solutions provider, process integration as an innovation driver, complete machining of gears using a TurnMill center with an integrated hobbing unit, fine boring and honing on machining centers, free of twist turning, combined turning and grinding, high pressure cooling, and cryogenic machining. The document then provides details on some of these topics, including concepts for milling, turning and gearing using modular machines, and examples of results from fine boring and honing processes.
The Nigeria Alternative Energy Expo 2012 is Nigeria’s leading alternative energy Expo. NAEE 2012 takes place at the Yaradua Convention Centre, Abuja Nigeria from September 17-19 2012. The event will feature an impressive line-up of local and international speakers, delegates and exhibitors, who will gather to debate a new energy future for Africa's most populous nation
Hybrid processes combine multiple manufacturing technologies to overcome limitations of conventional machining. This presentation defines hybrid processes as combining active principles that significantly influence the machining process. It provides examples of hybrid technologies like vibration-assisted machining, laser-assisted machining, and combinations of EDM/ECM with other processes. The goal of hybrid processes is to enable machining of difficult materials more efficiently.
This document provides an overview of diffuser films and hard coated films from Busines Unit CAS / FUNCTIONAL FILMS. It discusses the optical properties and applications of various Makrofol films for light management and electroplated parts, including LM 309, LM 905, LM 228, LM 322, and LM 243 diffuser films. It also presents the new ViviTouch technology in Mophie's Pulse mobile game controller.
The document discusses inkjet printing of functional materials on plasma treated surfaces. It explores using a μPlasma printhead to selectively treat substrate surfaces, improving their wetting behavior and allowing for more precise inkjet printing. Experiments showed that plasma treatment increased surface energy and wettability over time. Small plasma spots around 1mm in diameter were achieved and enabled localized inkjet printing within the treated areas at high resolution. A design of experiments approach was used to model how plasma spot size could be influenced by varying print height and number of treatments.
This document provides an overview of Sadanand's 4-week industrial training at the Sheet Metal and Fabrication Shop of Lohia Corp. Limited. It begins with a brief history of Lohia Corp and an introduction to sheet metal. It then describes the key processes in the sheet metal department like shearing, punching, bending, and welding. Several CNC and manual machines used are outlined like the Amada VIPROS 255 CNC press, 340-ton bending press, MIG welding, drilling machines, and Makino A92 machine. The training concluded with Sadanand gaining engineering skills for sack machine production and learning about key production principles and the importance of workers.
The Nigeria Alternative Energy Expo 2012 is Nigeria’s leading alternative energy Expo. NAEE 2012 takes place at the Yaradua Convention Centre, Abuja Nigeria from September 17-19 2012. The event will feature an impressive line-up of local and international speakers, delegates and exhibitors, who will gather to debate a new energy future for Africa's most populous nation
Hybrid processes combine multiple manufacturing technologies to overcome limitations of conventional machining. This presentation defines hybrid processes as combining active principles that significantly influence the machining process. It provides examples of hybrid technologies like vibration-assisted machining, laser-assisted machining, and combinations of EDM/ECM with other processes. The goal of hybrid processes is to enable machining of difficult materials more efficiently.
This document provides an overview of diffuser films and hard coated films from Busines Unit CAS / FUNCTIONAL FILMS. It discusses the optical properties and applications of various Makrofol films for light management and electroplated parts, including LM 309, LM 905, LM 228, LM 322, and LM 243 diffuser films. It also presents the new ViviTouch technology in Mophie's Pulse mobile game controller.
The document discusses inkjet printing of functional materials on plasma treated surfaces. It explores using a μPlasma printhead to selectively treat substrate surfaces, improving their wetting behavior and allowing for more precise inkjet printing. Experiments showed that plasma treatment increased surface energy and wettability over time. Small plasma spots around 1mm in diameter were achieved and enabled localized inkjet printing within the treated areas at high resolution. A design of experiments approach was used to model how plasma spot size could be influenced by varying print height and number of treatments.
This document provides an overview of Sadanand's 4-week industrial training at the Sheet Metal and Fabrication Shop of Lohia Corp. Limited. It begins with a brief history of Lohia Corp and an introduction to sheet metal. It then describes the key processes in the sheet metal department like shearing, punching, bending, and welding. Several CNC and manual machines used are outlined like the Amada VIPROS 255 CNC press, 340-ton bending press, MIG welding, drilling machines, and Makino A92 machine. The training concluded with Sadanand gaining engineering skills for sack machine production and learning about key production principles and the importance of workers.
1. Advancements in CAE and manufacturing technologies are providing opportunities for diversification and improvement in the metal casting industry. This includes award-winning optimized designs from topology optimization and simulations.
2. Companies are using these technologies to improve existing automotive and sports components, reducing weight by up to 50% while maintaining strength. This allows compliance with emissions regulations.
3. The technologies also enable feasible smaller production runs and diversification into new industries like tooling, with 3D printed fixtures. Overall these advancements are driving lighter, smarter, and more efficient product design.
Tamal Roy has 14 years of experience in new product development, design, project management, quality management, and team management. He is currently working as the Manager of R&D and Reliability at Carrier UTC in Jeddah, Saudi Arabia. His experience includes designing mechanical parts for locomotives, air conditioners, medical equipment, and refrigeration systems. He is proficient in CAD software, simulation, structural analysis, reliability analysis, and project management.
The document is an application for a design/engineering position with experience in mechanical engineering, CAD/CAM/CAE, plastics, R&D, mould design, new product design and development.
The applicant has over 10 years of experience in plastics mould and product design, reverse engineering, CAD, VAVE, jigs and fixtures, R&D, mockup validation, moulding and plastics/metal materials. They have worked with clients in the US, UK, Gulf, Germany, India and Asia on automotive, appliance, industrial, medical, aerospace and powertrain projects.
The applicant holds qualifications in plastics mould technologies, product design, mechanical engineering and
Here is a live demonstration of the Demag product configurator and how it interfaces with the Cadenas eCATALOG solutions system to generate CAD models.
[Achim Tymura proceeds to log into the Demag Designer tool and configure a drive system. As parameters are selected, he clicks a button to generate a CAD model. An XML file is sent to the Cadenas server, which then returns a 3D CAD model of the configured system in multiple formats].
You can see how quickly and easily CAD models can be generated based on the configuration selections. The integration between the Demag Designer tool and Cadenas backend allows engineers to explore design options in real-time without needing 3D modeling skills.
The document discusses ceramic and metal injection molding technologies used by maxon motor GmbH to produce small, complex parts with high precision. Key points:
- maxon uses ceramic injection molding (CIM) to produce ceramic parts that are extremely hard, wear resistant, and can work in harsh conditions. Metal injection molding (MIM) is used to produce steel parts in high volumes.
- CIM allows for complex, tiny ceramic parts that can have lifetimes up to 100 times longer than metal. MIM is used to replace multi-part assemblies with single parts.
- The document provides examples of applications like watch parts, nozzles, and sensors that benefit from the precision and properties of CIM and
This document provides personal and employment details of Hitesh K. Patel. It includes his contact information, education qualifications including a Bachelor of Engineering degree, and work experience spanning from 2007 to present in purchasing and quality control roles at various manufacturing companies in Ahmedabad, India. His most recent role is as Deputy Manager of Purchase at Steel Konnect India Pvt Ltd since 2014 where he is responsible for procurement activities for a heavy steel fabrication division.
IRJET- CFD Analysis of Spare Wheel Runner for using easy Car ParkingIRJET Journal
The document discusses a computational fluid dynamics (CFD) analysis of a spare wheel design that can rotate 360 degrees to aid in parking vehicles. It aims to address the challenge of limited parking space availability. The study models a spare wheel mechanism located under the vehicle that can move the car through rotation. Materials like iron steel, hard rubber, and alloy steel are considered. A prototype is modeled in Pro-E software and analyzed for structural validation using ANSYS. Results indicate the design has potential to make tight parking spaces and 360-degree maneuvers easier.
Additive manufacturing taking metal 3 d printing to the next level study b...Martin Erharter
The document discusses recent developments in additive manufacturing technologies, materials, and applications. It notes that powder bed fusion is currently the most mature and commonly used metal 3D printing technology. New technologies like binder jetting are expected to grow substantially in the coming years. Novel materials specifically designed for additive manufacturing like Scalmalloy and A20X are advancing towards commercialization. The document also examines trends in the additive manufacturing market, predicting consolidation among both printing service providers and machine manufacturers.
Dear students get fully solved assignments
Send your semester & Specialization name to our mail id :
help.mbaassignments@gmail.com
or
call us at : 08263069601
3D PRINTING IN AUTOMOBILE INDUSTRY.pptxSyedZayyanAli
3D printing in Automobile Industry.
Additive Manufacturing in Automobile Industry.
Application of Additive manufacturing.
Applications of 3D printing.
This presentation is all about Additive Manufacturing In Automobile Industry and Future In Automobile Industry.
Made By - ( Syed Zayyan Ali ) (B.tech 4th year) (MIT Moradabad).
#Engineering #Additive Manufacturing #Presentation
#3Dprintinginautomobileindustry
IRJET- Modeling & Analysis of a 100CC I.C. Engine Connecting RODIRJET Journal
1) The document describes modeling and static structural analysis of a 100cc internal combustion engine connecting rod using SOLIDWORKS and ANSYS.
2) Various materials were analyzed including aluminum alloys, steel, and a metal matrix composite. The connecting rod was subjected to a 400N force.
3) Analysis found the metal matrix composite had the least deformation but higher cost, while an aluminum alloy provided good results at lower cost for connecting rods.
This document summarizes a bachelor's thesis that analyzes how additive manufacturing (3D printing) could impact the after-sales services supply chain at Fokker Services B.V. The author identifies four key areas where 3D printing could help reduce costs: 1) addressing obsolescence issues when original parts are no longer available, 2) providing a lower-cost production alternative for some spare parts, 3) enabling part consolidation through redesign, and 4) potentially allowing for decentralization if airline operators invest in 3D printing. A data model is used to identify 235 spare parts that could benefit from 3D printing. Further analysis of 15 parts found 4 that are suitable for 3D printing and likely to provide cost savings
- KraussMaffei is a 170-year-old German engineering company specializing in plastics and rubber processing machinery.
- It is the world's largest producer of plastics machinery and offers injection molding, reaction processing, and extrusion technologies.
- The company has a global presence with 12 production plants, 38 sales offices, and over 100 partner agencies worldwide.
This document discusses a finite element analysis of the natural frequencies of an aluminum cylinder head cover (CHC). It begins by introducing the use of finite element modeling in automotive component design. It then describes modeling the CHC geometry in HyperWorks, generating a mesh, applying material properties and constraints, and performing a modal analysis in OptiStrut. The results identify the natural frequencies of the first six modes for the original design and an altered design with half the thickness. The minimum natural frequency of 1195 Hz for the original design is above the expected engine vibration frequency, indicating the design is safe from resonance failure.
Vibration in IC engines is a significant factor to be considered while designing IC engine as it can have a negative impact on various engine components. This happens when the natural frequency of component coincides with the forced frequency produce by the engine leading to the phenomenon of resonance.
This document provides a DFM (design for manufacturing) report for an injection molding project. It includes:
1. Base information for the two cavity mold such as materials, part size and weight, mold steel types, and the 1000 ton injection machine.
2. An index of 11 sections in the DFM report covering topics from part design optimization to mold layout.
3. Analysis of potential sink marks on the part with proposed design changes to reduce wall thicknesses and eliminate risks.
4. Evaluation of draft angles and need for changes to facilitate demolding.
5. Discussion of part marking requirements and surface finish specification.
6. Evaluation of the parting line design and
NEW APPROACH TO CASTING DEFECTS CLASSIFICATION AND OPTIMIZATION BY MAGMA SOFTIAEME Publication
Foundry industry suffers from poor quality and productivity due to the large number of process parameters, combined with lower penetration of manufacturing automation and shortage of skilled workers compared to other industries. Global buyers demand defect-free castings and strict delivery schedule, which foundries are finding it very difficult to meet.
This document discusses a new approach to classifying and optimizing casting defects using MAGMA software. It presents a 3-step method: 1) Classifying defects based on appearance, size, location etc. to correctly identify them; 2) Analyzing defects using historical data, cause-effect diagrams and design of experiments; 3) Optimizing the casting process by simulating mold filling, solidification and cooling in MAGMA to predict defect locations and optimize casting conditions to reduce defects. The methodology is applied to an axle housing casting, developing a proposed gating system design in MAGMA to identify potential porosity spots and refine the design to minimize defects. This approach is estimated to reduce casting rejections from 60%
This document discusses a new approach to classifying and optimizing casting defects using MAGMA software. It presents a 3-step method: 1) Classifying defects based on appearance, size, location etc. to correctly identify them; 2) Analyzing defects using historical data, cause-effect diagrams and design of experiments; 3) Optimizing the casting process by simulating mold filling, solidification and cooling in MAGMA to predict defect locations and rectify the process. This approach is estimated to reduce casting rejections from 60% to 15% by eliminating defects like blowholes, shrinkage and cold shuts through gating system optimization and process validation in MAGMA before manufacturing.
The document discusses adhesive bonding as an alternative joining method to welding, soldering, mechanical fasteners, and other techniques. It covers bonding theory, surface treatment methods, adhesive types, design considerations, examples of bonding applications, and trends in the industry. Success in bonding projects requires close collaboration between the customer, adhesive manufacturer, and equipment suppliers from the initial design phase.
1. Advancements in CAE and manufacturing technologies are providing opportunities for diversification and improvement in the metal casting industry. This includes award-winning optimized designs from topology optimization and simulations.
2. Companies are using these technologies to improve existing automotive and sports components, reducing weight by up to 50% while maintaining strength. This allows compliance with emissions regulations.
3. The technologies also enable feasible smaller production runs and diversification into new industries like tooling, with 3D printed fixtures. Overall these advancements are driving lighter, smarter, and more efficient product design.
Tamal Roy has 14 years of experience in new product development, design, project management, quality management, and team management. He is currently working as the Manager of R&D and Reliability at Carrier UTC in Jeddah, Saudi Arabia. His experience includes designing mechanical parts for locomotives, air conditioners, medical equipment, and refrigeration systems. He is proficient in CAD software, simulation, structural analysis, reliability analysis, and project management.
The document is an application for a design/engineering position with experience in mechanical engineering, CAD/CAM/CAE, plastics, R&D, mould design, new product design and development.
The applicant has over 10 years of experience in plastics mould and product design, reverse engineering, CAD, VAVE, jigs and fixtures, R&D, mockup validation, moulding and plastics/metal materials. They have worked with clients in the US, UK, Gulf, Germany, India and Asia on automotive, appliance, industrial, medical, aerospace and powertrain projects.
The applicant holds qualifications in plastics mould technologies, product design, mechanical engineering and
Here is a live demonstration of the Demag product configurator and how it interfaces with the Cadenas eCATALOG solutions system to generate CAD models.
[Achim Tymura proceeds to log into the Demag Designer tool and configure a drive system. As parameters are selected, he clicks a button to generate a CAD model. An XML file is sent to the Cadenas server, which then returns a 3D CAD model of the configured system in multiple formats].
You can see how quickly and easily CAD models can be generated based on the configuration selections. The integration between the Demag Designer tool and Cadenas backend allows engineers to explore design options in real-time without needing 3D modeling skills.
The document discusses ceramic and metal injection molding technologies used by maxon motor GmbH to produce small, complex parts with high precision. Key points:
- maxon uses ceramic injection molding (CIM) to produce ceramic parts that are extremely hard, wear resistant, and can work in harsh conditions. Metal injection molding (MIM) is used to produce steel parts in high volumes.
- CIM allows for complex, tiny ceramic parts that can have lifetimes up to 100 times longer than metal. MIM is used to replace multi-part assemblies with single parts.
- The document provides examples of applications like watch parts, nozzles, and sensors that benefit from the precision and properties of CIM and
This document provides personal and employment details of Hitesh K. Patel. It includes his contact information, education qualifications including a Bachelor of Engineering degree, and work experience spanning from 2007 to present in purchasing and quality control roles at various manufacturing companies in Ahmedabad, India. His most recent role is as Deputy Manager of Purchase at Steel Konnect India Pvt Ltd since 2014 where he is responsible for procurement activities for a heavy steel fabrication division.
IRJET- CFD Analysis of Spare Wheel Runner for using easy Car ParkingIRJET Journal
The document discusses a computational fluid dynamics (CFD) analysis of a spare wheel design that can rotate 360 degrees to aid in parking vehicles. It aims to address the challenge of limited parking space availability. The study models a spare wheel mechanism located under the vehicle that can move the car through rotation. Materials like iron steel, hard rubber, and alloy steel are considered. A prototype is modeled in Pro-E software and analyzed for structural validation using ANSYS. Results indicate the design has potential to make tight parking spaces and 360-degree maneuvers easier.
Additive manufacturing taking metal 3 d printing to the next level study b...Martin Erharter
The document discusses recent developments in additive manufacturing technologies, materials, and applications. It notes that powder bed fusion is currently the most mature and commonly used metal 3D printing technology. New technologies like binder jetting are expected to grow substantially in the coming years. Novel materials specifically designed for additive manufacturing like Scalmalloy and A20X are advancing towards commercialization. The document also examines trends in the additive manufacturing market, predicting consolidation among both printing service providers and machine manufacturers.
Dear students get fully solved assignments
Send your semester & Specialization name to our mail id :
help.mbaassignments@gmail.com
or
call us at : 08263069601
3D PRINTING IN AUTOMOBILE INDUSTRY.pptxSyedZayyanAli
3D printing in Automobile Industry.
Additive Manufacturing in Automobile Industry.
Application of Additive manufacturing.
Applications of 3D printing.
This presentation is all about Additive Manufacturing In Automobile Industry and Future In Automobile Industry.
Made By - ( Syed Zayyan Ali ) (B.tech 4th year) (MIT Moradabad).
#Engineering #Additive Manufacturing #Presentation
#3Dprintinginautomobileindustry
IRJET- Modeling & Analysis of a 100CC I.C. Engine Connecting RODIRJET Journal
1) The document describes modeling and static structural analysis of a 100cc internal combustion engine connecting rod using SOLIDWORKS and ANSYS.
2) Various materials were analyzed including aluminum alloys, steel, and a metal matrix composite. The connecting rod was subjected to a 400N force.
3) Analysis found the metal matrix composite had the least deformation but higher cost, while an aluminum alloy provided good results at lower cost for connecting rods.
This document summarizes a bachelor's thesis that analyzes how additive manufacturing (3D printing) could impact the after-sales services supply chain at Fokker Services B.V. The author identifies four key areas where 3D printing could help reduce costs: 1) addressing obsolescence issues when original parts are no longer available, 2) providing a lower-cost production alternative for some spare parts, 3) enabling part consolidation through redesign, and 4) potentially allowing for decentralization if airline operators invest in 3D printing. A data model is used to identify 235 spare parts that could benefit from 3D printing. Further analysis of 15 parts found 4 that are suitable for 3D printing and likely to provide cost savings
- KraussMaffei is a 170-year-old German engineering company specializing in plastics and rubber processing machinery.
- It is the world's largest producer of plastics machinery and offers injection molding, reaction processing, and extrusion technologies.
- The company has a global presence with 12 production plants, 38 sales offices, and over 100 partner agencies worldwide.
This document discusses a finite element analysis of the natural frequencies of an aluminum cylinder head cover (CHC). It begins by introducing the use of finite element modeling in automotive component design. It then describes modeling the CHC geometry in HyperWorks, generating a mesh, applying material properties and constraints, and performing a modal analysis in OptiStrut. The results identify the natural frequencies of the first six modes for the original design and an altered design with half the thickness. The minimum natural frequency of 1195 Hz for the original design is above the expected engine vibration frequency, indicating the design is safe from resonance failure.
Vibration in IC engines is a significant factor to be considered while designing IC engine as it can have a negative impact on various engine components. This happens when the natural frequency of component coincides with the forced frequency produce by the engine leading to the phenomenon of resonance.
This document provides a DFM (design for manufacturing) report for an injection molding project. It includes:
1. Base information for the two cavity mold such as materials, part size and weight, mold steel types, and the 1000 ton injection machine.
2. An index of 11 sections in the DFM report covering topics from part design optimization to mold layout.
3. Analysis of potential sink marks on the part with proposed design changes to reduce wall thicknesses and eliminate risks.
4. Evaluation of draft angles and need for changes to facilitate demolding.
5. Discussion of part marking requirements and surface finish specification.
6. Evaluation of the parting line design and
NEW APPROACH TO CASTING DEFECTS CLASSIFICATION AND OPTIMIZATION BY MAGMA SOFTIAEME Publication
Foundry industry suffers from poor quality and productivity due to the large number of process parameters, combined with lower penetration of manufacturing automation and shortage of skilled workers compared to other industries. Global buyers demand defect-free castings and strict delivery schedule, which foundries are finding it very difficult to meet.
This document discusses a new approach to classifying and optimizing casting defects using MAGMA software. It presents a 3-step method: 1) Classifying defects based on appearance, size, location etc. to correctly identify them; 2) Analyzing defects using historical data, cause-effect diagrams and design of experiments; 3) Optimizing the casting process by simulating mold filling, solidification and cooling in MAGMA to predict defect locations and optimize casting conditions to reduce defects. The methodology is applied to an axle housing casting, developing a proposed gating system design in MAGMA to identify potential porosity spots and refine the design to minimize defects. This approach is estimated to reduce casting rejections from 60%
This document discusses a new approach to classifying and optimizing casting defects using MAGMA software. It presents a 3-step method: 1) Classifying defects based on appearance, size, location etc. to correctly identify them; 2) Analyzing defects using historical data, cause-effect diagrams and design of experiments; 3) Optimizing the casting process by simulating mold filling, solidification and cooling in MAGMA to predict defect locations and rectify the process. This approach is estimated to reduce casting rejections from 60% to 15% by eliminating defects like blowholes, shrinkage and cold shuts through gating system optimization and process validation in MAGMA before manufacturing.
The document discusses adhesive bonding as an alternative joining method to welding, soldering, mechanical fasteners, and other techniques. It covers bonding theory, surface treatment methods, adhesive types, design considerations, examples of bonding applications, and trends in the industry. Success in bonding projects requires close collaboration between the customer, adhesive manufacturer, and equipment suppliers from the initial design phase.
The document discusses achieving reliable micro interconnections with long lifetime expectations. It describes common failure mechanisms for solder and adhesive micro interconnects, such as fatigue, creep, corrosion and brittle fracture. It also discusses how to improve interconnect design through careful material selection, understanding failure mechanisms, analyzing stress conditions, improving product design with modeling, and exploring new technologies like laser-induced forward transfer. The goal is to create systems with enhanced lifetimes through optimized interconnect design and technology.
Benjamin Mehlmann - Fraunhofer InstituteThemadagen
This document discusses laser micro joining processes and applications in research and development. It outlines laser beam sources and beam manipulation strategies used for micro joining applications in energy storage, electronics, and lightweight construction. Current approaches in research include welding copper with spatial and temporal power modulation to increase weld depth and quality. Developments aim to enable precision melt engineering through dynamic beam manipulation and modeling of laser micro joining processes.
This document discusses organic photovoltaic (OPV) technology and the Solliance OPV Program. The program aims to develop a complete technology toolbox for OPV to improve efficiency, lifetime, and lower costs. Current status shows efficiencies over 10% in the lab but lower efficiencies in modules. The program focuses on both solution processing and evaporated OPV using scalable printing and coating techniques. The goal is to achieve over 13% cell efficiency, 5% module efficiency, and manufacturing costs below €0.50/Wp by 2015.
This document provides an overview of a presentation on organic and printed electronics. The presentation covers topics such as OLED lighting and its potential market impact if OLEDs capture 10% of the lighting replacement market. It also discusses flexible OLEDs and OPVs, noting their potential applications in rollable, wearable, and easily integrated devices. The presentation reviews roll-to-roll manufacturing processes for these applications and the importance of techniques like slot die coating to enable low-cost, large-area production. It emphasizes the need for strict contamination control in OLED manufacturing. Finally, it provides a high-level summary and introduces the Holst Centre's work on large-area printing and coating technologies.
The document provides an introduction to organic and printed electronics. It discusses several societal challenges such as an aging population, increasing costs of healthcare, food waste, and energy needs. Organic and printed electronics offer advantages like low cost production using printing processes, flexibility, and lower environmental impact. Examples of applications mentioned include flexible displays, plastic solar cells, RFID tags, and electronic textiles. The market for printed electronics is predicted to grow substantially over the coming years across various industries such as healthcare, consumer packaging, and displays.
The document discusses research on smart materials for conformable electronics and photonics being conducted by Holst Centre. Holst Centre is an independent research organization co-founded by IMEC and TNO that focuses on creating generic technologies for flexible electronics. The presentation provides an overview of Holst Centre's work on organic light-emitting diodes (OLEDs) including applications, lifetime considerations, conformable technology approaches, and a vision for conformable electronic and photonic systems featuring wearable and stretchable designs.
Avantes is a developer and manufacturer of compact spectrometers, light sources, fiber optics, and accessories. It has sold over 17,000 spectrometers since 1994 and has annual worldwide sales of 10 million euros. Avantes uses its core spectrometer technology across multiple markets including life sciences and health, industrial processes, optical diagnosis spectroscopy and imaging, safety and security, agriculture and food, and green energy and environment. The document provides examples of spectroscopy applications for Avantes' products in areas such as LED measurements, solar panel measurements, thin film measurements, blood analyses, and food quality analysis.
The document describes the development of a low-cost ammonia sensor called the miniDOAS that uses UV spectrometry. It was created to address the need for more affordable ammonia monitoring by adapting the established Differential Optical Absorption Spectroscopy (DOAS) technique using less expensive components. Testing showed it can measure ammonia concentrations comparably to the research-grade RIVM DOAS system, but at a fraction of the cost. Further development aims to commercialize the miniDOAS for wider air quality monitoring and research applications.
1) Additive manufacturing (AM) opens revolutionary opportunities for high tech equipment development by enabling new and innovative mechatronic system designs.
2) AM can help address challenges for high tech equipment like improving accuracy, productivity, and reducing costs by providing ultimate design freedom and integration capabilities.
3) For high tech systems, AM enables new solutions like lightweight, integrated, and freeform designs which conventional manufacturing cannot achieve. AM moves manufacturing from "design for manufacturing" to "manufacturing for design."
1. New machining
concepts and
technologies for
advanced metal
cutting
2010/12/14
Dr.-Ing. Heiner Lang
Global Chi f Technical Officer
Gl b l Chief T h i l Offi
MAG IAS
AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 2
2. Milestones and Growth Strategies of MAG
04/2005 08/2007 - Cincinnati Machine
Cincinnati/Lamb MAG Russia - Lamb Technicon
10/2005 12/2007
ThyssenKrupp MetalCutting Kecskemét
- Cross Hüller
- Fadal
03/2006 09/2009
Ex-Cell-O MAG Brasil / Sao Paulo - Giddings & Lewis
New Sales & Service Facility - Hessapp
- Hüller Hille
01/2007 07/2010 - Witzig & Frank
MAG India MAG IAS GmbH
09/2010
MAG China / Changchun
01/2007 New Manufacturing Plant
Boehringer
10/2010
Samputensili, Chemnitz
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 3
MAG worldmap
3500 employees - world wide sales, engineering, production and service
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 4
3. Markets, Products, Applications
Industrial Equipment
Automotive Aerospace Renewable Energy
Rail, Construction, Power
OEMs, Truck
OEMs Truck, Commercial, Military, Space,
Commercial Military Space Wind, Solar
Generation,
Generation Oil & Gas,
Gas
Major Automotive Tier Helicopter Agriculture, General
Markets
Suppliers Machining, Marine
Machines and equipment
ations
Cylinder Heads & Blocks, Aluminum Structures, Large Frames, Bearings, Hubs, Solar Panels, Thin Film and C-
Cams, Cranks, Composite Structures, Planetary Carriers, Cases, Lift Si Solutions, Wind Blades and
Applica
Transmission, Chassis, Titanium Components, Arms, Wheel-Sets, Brake Root End Milling Machines
Wheels, Shafts, Engines, Landing Gear Disks, Drive & Chassis
Composite Panels Components, Engines, Shafts,
Pumps, Valves, Compressors
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 5
AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 6
4. The modular and communally building blocks are
developed,
developed used and expanded with CORCOM
CORCOM = Core Components
MAG in house technology
High communality/ Rotary tables for milling and
A-Axis turning operations
same and robust
product technology
Major advantages
j g
1. Flexibility / configuration
2. Cost-effective
3. Robust product design
B-Axis 4. Shortest delivery time B- on A-axis
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 7
Process Integration as Innovation Driver
- Customized Solutions -
Building Blocks
ard
Horizontal Vertical
B
Standa
Vertical Horizontal
Machining Machining
Turning Centers Turning Centers
Centers Centers
Turning Milling Hobbing Cold
Drilling Forming Laser Honing Grinding
hnologyy
odules
tomized Tech
Mo
d
Customized Solution
olution
- Base machine + standardized interfaces
- Configurable Technology/Softwaremodules
Cust
So
- U ifi d operator-, automation- and service
Unified t t ti d i
concept, similar parts
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 8
5. AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 9
Concept for Milling, Turning and Gearing (Modular
concept of base machine)
ƒ Vertical turning center as Base machine
g
- Modular expendable to 4ax (2 turrets)
- One or two turn tables
- 2ax milling spindle with tilting unit
- Vertikal RAM for heavy turning processes
- Hobbing unit for g
g gearing
g
ƒ Process integration
- Moduls for turning, milling, gearing, grinding
/
B/Y-axis
turret RAM spindle Hobbing
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 10
6. Technology Modules:
- 3-axis Swivel unit for gear milling operations
- Hobbing unit for gear manufacturing
Bi-functional Milling Spindel
Bi f ti l Milli S i d l Hobbing U it
H bbi Unit
Swivel Range: +/- 105 Swivel Range: +/- 30
Max. RPM: 5000 1/min Max. RPM: 600 1/min
Torque at 40%:
q ED 380 Nm Modul: bis 6 mm
Power at 40%: ED 36 kW Shifting Stroke: 200 mm
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 11
Concept for Milling, Turning and Hobbing in one
machine tool
Hobbing Unit (H400)
5ax Unit for: for Outside gearing
- Milling
- Drilling
- Winding
- Turning
Z- axis vertical 600mm
X- axis horizontal 300 mm
Y- axis shift 200 mm
A-
A axis vertikal 30
C- axis main spindle
Tool magazine
High precision
Table
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 12
7. Work piece data
Piece
MAG hobbing unit
Material 18CrNiMo6 H400
Normal modul 6
Work piece
Angle of profile 20 spur gear
Number of teeth 85
Pitch angle 18 right
clamping mandrel
Outside-‡ 548 mm Clamping ø 205 mm
Root-‡ 521 mm
Gear teeth width 85 mm
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 13
Complete process chain for cutting process
(Productivity comparison)
Single cut process Multi Task process
6 Machine tool : 3 1
6 Setting up: 30 min 10 min
6 L di / Rigging:
Loading Ri i 6 min
i 3 min
i
6 Process: 32.2 min 36.6 min
6 Unloading / Cleaning: 6 min 3 min
Cycle time first piece: 74.2 min 52.6 min
Cycle time following pieces: 44.2 min 42.6 min
Time reduction per piece: 1.6
1 6 min
ƒ Multi task process allows reducing of cycle time
g y
ƒ Productivity increasing result from minimized nonproductive times
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 14
8. AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 15
Definition Honing
TARGET: functionally optimized surface and geometry of bores
stroke
What is honing? Why honing?
Honing is a cutting method Higher lifetime at
for the correction of ƒ high power output
ƒ diameter ƒ less consumption
ƒ shape
h ƒ low emissions
ƒ surface ƒ less wear
ƒ positional tolerances of ƒ better emergency
bores running properties
Radial Rotational motion of
expansion of the tool
the honing
stones
The surface is characterized by its cross-hatch
structure.
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 16
9. Advantages by Honing on Horizontal Machining
Centre
Your B
Y Benefit
fit
ƒ Cost efficient solution compared to a separate, special honing machine
ƒ Less honing operations due to improved pre-machining
ƒ Less honing time due to reduction of stock and stock variation
ƒ One partner for the whole
production li
d ti line
ƒ Elimination of bottleneck
honing machine
ƒ Expandable honing tools
integrated in the standard
tool magazine
ƒ Automatic tool change
ƒ Scalability of the complete
production line matched to the
actual production volume
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 17
Draw Bar Spindle HSK100 GEN4
ƒ Synchronous-spindle HSK 100
ƒ 5000 1/min
ƒ 28 kW and 150 Nm
ƒ Integrated draw bar (
g (driven by
y
torquemotor and ball screw drive)
ƒ Highly dynamic feed system
Acceleration: 10 m/s² Speed:
10 m/min
ƒ Integrated channels for air gauging and
coolant through the spindle
ƒ Integrated axial force measurement
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 18
10. Results after Base Honing
Test results after base honing
ƒ Fax-Film (magnifaction 100-times) and surface
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 19
Results after Plateau Honing
Test results after plateau honing
ƒ Cylindricity: < 3,5 μm
ƒ Roundness: < 2 μm
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 20
11. AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 21
Drallfrei
Hart
Hart- und Weichdrehen auf einer VDF T
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 22
12. Grinding – Standard machining for finishing process
Advantages:
Ad t
ƒ Well known process, long life experience
ƒ High process quality and reliability
ƒ Good work piece surface and process
stability due to coolant use
Disadvantages:
Di d t
ƒ High investment cost – separate machine
ƒ Coolant required./ No dry machining
ƒ S f
Surface quality d
li depended on corn fi
d d finess
ƒ Real Free of Twist surface only achievable
when sparking out several times
ƒ LLong process / cycle ti
l time
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 23
New process: Free of Twist Turning
Underline:
2 1 Shaft
1a Machined Surface
2 Tool Holder
3 2a
2a Cutting Blade
D 3 Feed motion direction
7 Shaft rotation
10 Shaft axial axis
D Angle of Inclination
1a 1 Advantages:
ƒ Applicable on turning machines
ƒ Free of Twist surfaces
ƒ Typical Rz-value: 2-3 μm
Alternative to Hard Turning or Grinding
Much faster process / cycle time than Grinding
Longer Tool life than conventional carbide turning insert or grinding weel
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 24
13. Test result: Free of Twist Turning of sealing surface
Hard Turning
H dT i Free of Twist Turning
F fT i tT i Surface Topology of FoT Turning
S f T l fF TT i
CLA 19 μin CLA 10 μin
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 25
Comparison: Hard Turning vs. Free of Twist Turning
Hart Turning: Free of Twist Turning:
ƒ Parameters: ƒ Parameters:
– fz = 0,10 mm – fz = 0,50 mm
– r = 0,8 mm – fy = 0,08 mm
y
– ap = 0,15 mm – ap = 0,15 mm
– l = 165 mm – l = 165 mm
ƒ Result: ƒ Result:
– Roundness = 3,5 μm – Roundness = 3 μm
– t = 124 sec – t = 25 sec
Opportunities: Steering Knuckle Machining Results:
ƒ Performance increase: ƒ Free of Twist Turning of
Hart vs. FoT Turning 5 : 1 sealing surface
ƒ Longer Tool life 1 : 10 R 0 2 - 0 5 Pm
Ra 0,2 0,5
Rz d 2 Pm
ƒ Roundness of bearing
diameter d 3 Pm
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 26
14. AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 27
Combined Hard Turning and Grinding
Hardturning of face Finishgrinding f
Fi i h i di of
and shell surface bore hole
Finishgrinding of Measuring of
the keyway bore and keyway
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 28
15. Vertical turning machine for flange parts
Z-Slide ith t
Z Slid with turret for
tf
hard turning
Integrated measuring
probe for quality
check
Z-Slide with
Grinding Spindle Z-Slide with motorized
spindle to attach
crossheads for grinding
key ways or slots.
Y-axis integrated to
adjust feed
j
Workpiece table
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 29
Turret for Hard Turning
Z-Slide with turret for
hard turning
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 30
16. Spindle for cylindrical Grinding
Z-Slide ith
Z Slid with
Grinding Spindle
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 31
Spindle with attachment
Z Slide
Z-Slide with motorized
spindle to attach
crossheads for grinding
key ways or slots.
Y-axis i t
Y i integrated to
t dt
adjust feed
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 32
17. AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 33
High Pressure Cooling
Goals:
Increase Tool Life
Increase Cutting Parameters
Better Chip Formation
Intensive Cooling of tool and workpiece
Applkication Area:
Machining of materials with difficult cutting behavior
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 34
18. What is High Pressure Cooling
Effectiveness:
High Pressure Coolant flow between chip and tool
ÖPressure approx. 100 – 400 bar
ÖDue to high pressure the coolant gets closer to the tool
center point
ÖReduction of tool wear due to better friction behavior
ÖBetter cooling of tool and up to 50% lower temperature in
contact zone Span
Ö Better chip breakage and chip formation
Schneide
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 35
High Pressure Cooling
Results:
Increase of tool life up to 50%
Increase of cutting speed up to 50%
g p p
Chip formation
Low pressure
High pressure
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 36
19. Applications
Typical fields of application:
Mill-Turning of complex parts and materials
Increase of chip removal rate
Better chip evacuation
Industry sector:
Mainly Aerospace
Titanium and Alloys
Nickel based alloys
-- Inconel
-- Hastolloy
Other fields of application:
Low carbon steels due to better chip breakage
Al-alloys due to reduced adhesive wear and avoidance of build-up edge
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 37
MAG test machine for customer applications
Working room
g
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 38
20. Application: Titanium Cutting
Turning of Titanium: Tool Life
Conventional Cooling
Material:
Ti6AlV4 High Pressure Cooling
Cutting Parameters:
Vc=60m/min
ap=2,5mm
f=0,25mm/rot
f=0 25mm/rot
Vc [m/min]
Conventional Cooling High Pressure Cooling
After 2 min After 4 min
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 39
Customer Applications @ MAG
Industry Sector: Turbine Parts
8 CNC-Turning Machines for
Airplane Turbine Parts have
p
been delivered along with High
Pressure Cooling
Work Piece: Planet Carrier
Turning, Drilling, Milling on
MAG TurnMill Center
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 40
21. AGENDA - Process Integration and new
Technologies in Powertrain Applications
1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)
4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)
5. Free of Twist Turning
(Approach to significantly improve turning quality)
6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)
7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)
8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 41
Current Machining is Speed Limited
ƒ Machining generates heat at the
cutting edge due to friction,
shearing,
shearing and abrasion Rapid
Tool Wear
To Flank We (mm)
ƒ Once a critical speed is exceeded,
ear
Cutting
g
wear increases rapidly Speed Limit
ool
ƒ Occurs because conventional
coolants provide insufficient heat
removal to enable order-of-
magnitude i
it d increases i speed
in d
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 42
22. The Unique Application of MAG Cryogenic Venting
Conventional MAG
LN2 & CO2
Cryogenic
application
Vented,
Heat-sink
application
External only RAKE FACE
Cryogenic flow External Cryo
CHIP
&/or MQL Flow
FLOW
-321 F
321
SHEAR
PLANE
The MAG model plumbs the cooling
Prior nitrogen cooling applications flow through the insert to allow a
were all external, like conventional heat-sink effect rather than chip
coolants, aimed at the face of the zone cooling.
Heiner Langand chip.
insert Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 43
Our Solution – MAG Cryogenic Technology
ƒ MAG Cryogenic Technology uses small flow rates of liquid nitrogen
(LN2) applied near the cutting edge (directly and indirectly) to maximize the
cooling effectiveness (~0.04 to 0.08 L/min/cutting edge)
ƒ MAG has licensed the Intellectual Property of cryogenic machining
ƒ Cryogenic processing replaces traditional cutting fluids with more
environmentally friendly cryogenic fluid that enables higher cutting speeds:
ƒ Environmental, Health & Safety Advantages:
– Nitrogen is an inert atmospheric gas which is
78% of the air we breath
– Very easily safeguarded with an Oxygen sensor
– LN2 is a non Greenhouse gas
– Safe non slip coolant system for large
walk-on machine t bl
lk hi tables
– Contamination free for Medical
machining requirements
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 44
23. Key Advantages – MAG Cryogenic Technology
ƒ Machining Performance
– 4X increase in processing speed for CGI
– 2-3X increase in processing speed for titanium
– 10X improvement in tool life for titanium 0.24 L/min of Liquid Nitrogen (ICS)
10
10X Improvement
min)
Tool Life (m
5X Improvement
1
15 L/min Flood Coolant
0.1
200 300 400 500
Surface Speed (ft/min)
40% Longer Cycle Time in
g y Dramatic Improvement in
Titanium for Flood Coolant Tool Life and Speed
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 45
MAG Cryogenic Performance Data - Titanium
Workpiece Material Operation Speed Results
300 SFPM (91 M/min.) 300 SFPM: 6 min. of in cut time (3 for flood) (2X)
Titanium Plunge Milling
400 SFPM (122 M/min.) 400 SFPM: 2 min. of in cut time (1 for flood) (2X)
Tool:
T l KMT 2 inch Pl
i h Plunge Mill with 5 Fl t
ith Flutes
Insert: SDCT120432ENLD2-KC725
Width of Cut: 0.875 inches
Plunge Depth: 1 inch Liquid Nitrogen
Stepover: 0.350 inches
CLPT: 0.00314 in/tooth
10
0.76 L/min of Liquid Nitrogen (ICS)
Tool Life (min)
2X Improvement
p Flood Coolant
L
35 L/min Flood Coolant 2X Improvement
1
200 300 400 500
00
[91 M/min] [122 M/min]
Surface Speed (ft/min)
Cryo Modified KMT 2 inch Plunge Mill
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 46
24. How Can You Get MAG Cryogenic Technology?
ƒ Portable Rotary Cryogenic Adapter (
y y g p (RCA) )
ƒ Test various materials, specific challenges, and
processing bottle necks without changing the machine
ƒ Evaluate MAG Cryogenic Technology
ƒ Cooperatively develop optimum machining parameters
ƒ Secure “Voice of the Customer” feedback and
sponsorship
hi
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 47
Technology, Speed, Flexibility & Service!
Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 48