Intefix Open Call Webinar. INTEFIX aims to increase the performance of the machining processes by the 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.

1. INTElligent FIXtures for the manufacturing
of low rigidity components
Grant agreement no: 609306
WEBINAR: INTEFIX OPENCALL
Oscar Gonzalo
21/03/2014
This project is part of the I4MS initiative

2. CONTENTS
• INFORMATION ABOUT THE PROJECT
• Objectives
• General structure
• Management
• Opencall• Opencall
• DESCRIPTION OF CURRENT CASE STUDIES
• REMARKS FOR THE OPENCALL APPLICANTS

3. Partners: 22
Starting date: July 2013
Ending date: June 2016
Duration: 3 years/36 month
Budget: 9.639.391 €
PROJECT DATA
EC contribution: 7.499.998 € (including the OPENCALL)
OPENCALL:
EC contribution: 1.450.000 €
Call closure date: April 2nd 2014
Minimum number of new experiments: 3

4. INTRODUCTION
Manufacturing:
machining processes Machine Fixture Process
FIXTURE:
• Securely HOLD and accurately LOCATE the workpiece
• Affects PRECISION, QUALITY and COST

5. INTEFIX APPROACH
CONCEPTS:
INTELLIGENT
FIXTURES
Monitoring (sensors)
Control
Adaption (actuators)
Precision
Quality
Cost
CONCEPTS:
• Mechatronic/Adaptronic systems
• Adaptability (Tunable behaviour)
• Modularity (Modular elements)
• Flexibility (Other applications: welding,
assembly...)

6. INTEFIX APPROACH
VIBRATION
POSITIONINGPOSITIONING
DEFORMATION

7. 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.
Experiments ⇒ MethodologyExperiments ⇒ Methodology
State of the art systems ⇒ Integration
Modular elements ⇒ Configurability & Reusability
Adaptive fixture ⇒ Intelligent fixtures – Fast and accurate

8. PROJECT STRUCTURE
• SCENARIO 1: VIBRATION [2]
• SCENARIO 2: DEFORMATION [4]
• SCENARIO 3: POSITIONING [2]
CASE STUDY n
EXPERIMENTS (18 months)
Selected case studies/aplications
SENSORS
ACTUATORS
SOFTWAREAND
ALGORITHMS
MONITORING
ANDCONTROL
FIXTURES
MACHINING
TECHNOLOGIES
CASE STUDY n
Coordinatingpartner
Technology
supplyers
End-user
RTD
performers
SENSORS
ACTUATORS
SOFTWAREAND
ALGORITHMS
MONITORING
AND
FIXTURES
MACHINING
TECHNOLOGIES
ALAVA
C-TEC
INVENT
AI
MATZAT
AI
COMPOTECH
STERN
C-TEC
BCT
IDEKO
TEKNIKER
TUDo
RCMT
OvGU/IFQ
IDEKO
TEKNIKER
RCMT
AI
MATZAT
ROEMHELD
GIGGEL
AI
COMPOTECH
INVENT
SORALUCE
ITP
DEHARDE
SORALUCE
GOIMEK
GIGGEL
TYC
KALEAERO

9. MANAGEMENT
Committees at different levels
• Steering
• Exploitation, IPR & dissemination
• Technical TECHNICAL COMMITTEE OvGU/IFQ-RCMT-
STEERINGCOMMITTEE
Membersto be appointedat Kick-Off
EXPLOITATION, IPR
and DISSEMINATION
COMMITTEE
Chairman:CECIMO
COORDINATOR
EU
WP Leaders• Technical
• General assembly
GENERAL ASSEMBLY
(The whole consortium)
NEW case studies through Open Calls
Scenario1:
Vibration
Case
Study 1
Case
Study 2
Scenario 2:
Deformation
Case
Study 1
Case
Study 2
Case
Study 3
Case
Study 4
Scenario3:
Positioning
Case
Study 1
Case
Study 2
TECHNICAL COMMITTEE OvGU/IFQ-RCMT-
IDEKO
Dissemination: CECIMO
Exploitation IPR: C-TEC
WP Leaders
Other participants

10. OPENCALL
Definition of the
problem
(Vibration/Distortion/
Positioning)
Form a
miniconsortium
Submission of the
proposal
Incorporation of new experiments to the project
Deadline for proposals submission: April 2, 2014
Evaluation results of the Opencall: May 29, 2014.
Start of the new experiments: July 1, 2014
Maximum EU contribution: up to 485.000 €/proposal

11. PROJECT PLANNING
Technical WPs from OPENCALL
ID WORK PACKAGE / TASK T 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
WP 13 Case study 0.1. Open call for the Scenario 1: Vibration 18
T 13.1 General analysis and definition of the fixture configuration 9
T 13.2 Development of the fixture control 9
T 13.3 Detailed design. Manufacturing and assembly of the test platform 6
T 13.4 Test. Verification and validation 3
WP 14 Case study 0.2. Open call for the Scenario 2: Deformation 18
T 14.1 General analysis and definition of the fixture configuration 9
T 14.2 Development of the fixture control 9
T 14.3 Detailed design. Manufacturing and assembly of the test platform 6
T 14.4 Test. Verification and validation 3
Year 1 Year 2 Year 3
T 14.4 Test. Verification and validation 3
WP 15 Case study 0.3. Open call for the Scenario 3: Positioning 18
T 13.1 General analysis and definition of the fixture configuration 9
T 15.2 Development of the fixture control 9
T 15.3 Detailed design. Manufacturing and assembly of the test platform 6
T 15.4 Test. Verification and validation 3

12. PROJECT PLANNING
GENERAL WPs
ID WORK PACKAGE / TASK T 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
WP 1 Project Management 36
T 1.1 Establish INTEFIX administration and methodologies for integrating project activities 3
T 1.2 Management and Coordination 36
T 1.3 Administration and Support activities 36
T 1.4 Open Call. Mechanism implementation 36
WP 2 Training, dissemination and exploitation 36
T 2.1 Training activities 36
T 2.2 Dissemination strategy and activities 36
T 2.3 Exploitation activities 36
T 2.4 Standardization activities 36
Year 1 Year 2 Year 3
T 2.4 Standardization activities 36
WP 3 Specifications 6
T 3.1 General specifications 6
T 3.2 Specifications of experiments in Scenario 1: Vibrations 6
T 3.3 Specifications of experiments in Scenario 2: Deformations 6
T 3.4 Specifications of experiments in Scenario 3: Positioning 6
T 3.5 Definition of the required specifications for the OPEN CALL case studies 6
WP 4 INTEFIX methodology development 12
T 4.1 Methodology for cases in Scenario 1: Vibrations 12
T 4.2 Methodology for cases in Scenario 2: Deformations 12
T 4.3 Methodology for cases in Scenario 3: Positioning 12

13. SCENARIO 1: VIBRATION
CS 1.1
Identification and active damping of critical workpiece vibrations in milling of thin-walled
impellers/blisks.
Description:
• Impeller made of EN AW-7075 aluminium by 5-axis milling.
• Reduce the vibrations in the machining of the blades.
• Integration of sensors and actuators for monitoring the process and for avoiding unstable conditions (chatter).
• Vibrations occurs due to low stiffness and cutting forces, resulting in unstable cutting, bad surface finishing and tool
wear.wear.
Partners:
• GIGGEL GmbH; ROEMHELD GmbH; INVENT GmbH; CEDRAT Technologies; ISF (TUDortmund); IFQ (OvGU-
Magdeburg)
Description of the solution:
• Development of an “i-chuck”: new chuck with
integrated sensors able to detect the unstable
cutting, also including actuators to counteract the
vibrations
• Use of dynamic simulations of the cutting process
as an input

14. Turning of low pressure turbine casing.
Description:
• Low pressure turbine case made of INCONEL 718. Dimensions: D=1800 mm; H=550 mm; e=2.5-6 mm.
• The process performance is limited by the vibrations, i.e. low cutting conditions and reduced tool life
• Vibrations result in bad surface finish and integrity ⇒ Potential component rejection (Scrap)
• Variable dynamic behaviour due to the material removal process
• Rotating workpiece in the vertical lathe
SCENARIO 1: VIBRATION
CS 1.2
Partners:
• ITP; INVENT GmbH; CEDRAT TECHNOLOGIES; COMPOTECH s.r.o.; ALAVA Ingenieros; ADAPTRONICS
International GmbH; IK4-TEKNIKER
Description of the solution:
• Integration of sensors and actuators
• Capability to detect the vibrations
• Modification of the system behaviour: machine-fixture-workpiece
• Modify the boundary conditions of the workpiece to change the dynamic behaviour:
force, pressure, damping ⇒ Modification of the stiffness and damping, adjusting of
the position and clamping force

15. SCENARIO 2: DEFORMATION
CS 2.1
Detection and compensation of workpiece distortions during machining of slender and thin-walled
aerospace parts.
Description:
• Estructural component made of aluminium for the aerospace sector
• Distortions occur due to the residual stresses and the high amount of material removed from the raw workpiece
• Out of tolerances workpieces
• Integrate systems to detect the distortions and compesate the deviations using actuators
Partners:
• DEHARDE; GIGGEL GmbH; ROEMHELD GmbH; INVENT GmbH; BCT; ISF (TUDortmund); IFQ (OvGU-Magdeburg)
Description of the solution:
• Integration of sensors to detect the force produce by the distortion in the control
point
• Integration of actuators to compensate the distortion
• Use an incremental machining strategy in different steps
• Adaption of the tool path to the deformed configuration

16. SCENARIO 2: DEFORMATION
CS 2.2
Clamping of thin-walled curved workpieces.
Description:
• Control of deformation of a thin walled structural component made of Al 7075 (L=3000 mm; W=1100mm; e=2-3 mm)
• Raw material: solid block
• Control of clamping forces and in process thickness measurement
• Worpiece turn over to machine both sides
• Variable stiffness during machining ⇒ Control of the clamping foce to minimize the deformation
• Control the final thickness. Error associated to deformation results in higher weight of lower stiffness
• Also limited by the vibrations ⇒ optimization of process parameters
Partners:
• RCMT; TYC s.r.o; ROEMHELD GmbH
Description of the solution:
• Integration of sensors to measure the clamping forces
• Control of the clamping force associated to workpiece stiffness
• Establish comunication between fixture and CNC
• Integration of sensors to measure the thickness

17. SCENARIO 2: DEFORMATION
CS 2.3
Distortions in aeronautical structural parts.
Description:
• Control of distortions in a slender structural aeronautic component, with intensive material removal
• Residual stresses from previous process and aditional stress due to clamping process
• Different clamping stages to achieve an undistorted component ⇒ reduced precision, high dispersion in the results, high
rejection rate
• Complicated fixture due to low and changing stiffness
• Currently the workpiece is supported using resin, resulting in long processes due to polymerization cicles• Currently the workpiece is supported using resin, resulting in long processes due to polymerization cicles
Partners:
• KALE AERO; DR. MATZAT; IK4-IDEKO
Description of the solution:
• Intelligent fixture to measure the clamping force and apply a controlled displacement
• Two steps: first look for contact, second fix without deformation
• Mathematical model of residual stress in the workpiece in each operation ⇒ Prediction
of the state after each machining stage
• Proposed machining process: correct and compensate the predicted distortion

18. SCENARIO 2: DEFORMATION
CS 2.4
Machining of aircraft turbine support structures.
Description:
• Structural component of an aircraft turbine made of INCONEL 718 (D=1900mm; H=350mm; e=6-10mm).
• Control of deformations during clamping due to distortions form previous processes (welding and heat treatment).
• Turning of different flanges to meet precision and tolerances.
• Rotating fixture and workpiece during machining.
• Also problems associated to vibrations
Partners:
• ITP; STERN Hidráulica; ALAVA Ingenieros; ROEMHELD GmbH; IK4-TEKNIKER
Description of the solution:
• Monitoring the initial shape of the component
• Sensors to measure deformations, clamping force and vibration
• Actuator to adapt the fixture to the deformed configuration. Adaption of the position
of the locators and clamping force
• Solution for the rotation motion: Power and signal integrated a rotating workpiece-
fixture (slip rings, wireless signal transmission)

19. SCENARIO 3: POSITIONING
CS 3.1
Fixture system for workpiece adjustment and clamping with/without its predeformation.
Description:
• Structural component made of steel for trains (L=2500mm; H=1500mm), with previous welding processes
• Reduction of the set-up time, improving the precision of the clamping process.
• Achieve a right positioning taking into account the deformed shape after clamping.
• Milling and drilling operations with limited precision due to deformations during clamping
• Introduction of systems to reduce the vibrations during machining
Partners:
• RCMT; TYC s.r.o; ROEMHELD GmbH; ADAPTRONICS International
Description of the solution:
• Modular fixture for the leveling of the workpiece
• Integration of sensors and actuators
• Independant and movable supports, able to measure the force and
position working in close loop

20. SCENARIO 3: POSITIONING
CS 3.2
Semiautomatic tool reference for application on large parts
Description:
• Big size components with miling and drilling operations
• Measuremnt of the position in the fixture/machine, and correction of the position by
displacement of the supports
• Avoid lack of material in the areas of interest
• Reduce error from deformation during clamping
• Reduce the set up time• Reduce the set up time
Partners:
• SORALUCE; GOIMEK; ROEMHELD GmbH; IK4-IDEKO
Description of the solution:
• Machine integrated vision system
• Modular fixture elements integrating force control and position
• Monitoring to minimize errors coming from clamping force distortions
• Aplication to machines with 2 pallet stations

21. REMARKS (I)
• Original Call: “Challenge 7 ICT for the enterprise and manufacturing” , “Objective
7.2: Equipment assessment for sensor and laser based applications”
• SME with own products: Technology suppliers (Strengthen supply-side SMEs )
• Supply manufacturers with new equipment and components for improved manufacturing
operations.
• Foster manufacturing industry (New application areas for the products of SME)• Foster manufacturing industry (New application areas for the products of SME)
• THEMATIC AREA of INTEFIX:
• MACHINING PROCESS
• Focus: IMPROVE THE FIXTURE (INTELLIGENCE by using sensors+actuators+control)

22. REMARKS (II)
• EXPECTATIONS FOR NEW EXPERIMENTS:
• Definition of a new Experiment/Case Study
• Identify the Scenario: Vibration / Distortion / Positioning
• New applications
• New solutions for the intelligent fixtures• New solutions for the intelligent fixtures
• Complementary the current experiments; ENHANCED IMPACT OF THE PROJECT
• Include all participants necessary for the experiment
• EVALUATION:
• Criteria: S/T quality; Implementation; Impact
• Carried out by external evaluators (At least 2 evaluations per proposal)

23. REMARKS (III)
• MINICONSORTIUM & Countries:
• Not specific requirements about the number of different countries
• MINICONSORTIUM & Number of Partners:
• Not specific requirements about the number of partners, at least:• Not specific requirements about the number of partners, at least:
• End-user: Defining the application for the experiments
• Technology supplier: systems to be integrated in the fixture
• Others: integration, control…
• MINICONSORTIUM & INTEFIX’s Partners:
• Partners already members of the consortium can participate
• EU contribution limited to 25% of the total case study (Maximum 25% of 485.000€)

24. REMARKS (IV)
• INTEGRATION in INTEFIX:
• Acceptance and Signature of the project Consortium Agreement
• Coordination between case studies: Share experiences and collaboration ⇒ Methodology
• Contribution to other activities:
• DISSEMINATION + TRAINING + “STANDARDISATION” (if possible) + NEW PRODUCTS
• 2 PM for the coordinating partner / 1 PM for other participants

25. REMARKS (V)
• Partners must have a PIC code
• Funding rates: As in FP7
• Work structured in a single WP of type RTD
• SME, RTD performers, Universities: 75%• SME, RTD performers, Universities: 75%
• Large Industry: 50%

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