Desenvolvimentos recentes para uma produção sustentável

Desenvolvimentos recentes para uma produção sustentável -

Recent Developments for a Sustainable ProductionDipl.-Ing Markus Röhner

Production Technology Centre Berlin

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I FraunhoferProduction Technology Centre Berlin (PTZ)

I Global TrendsThe Global Markets Beyond Tomorrow

I Brazilian MarketAerospace, Energy, Automotive

I Sustainable ProductionInnovations for your Production Systems

I Services of Fraunhofer IPKExample of Projects

I Fraunhofer IPK in BrazilCooperation Projects

I Contact

Agenda

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FraunhoferProduction Technology Centre Berlin

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The German R&D Innovation Chain

1. Basic research

2. Application-oriented research

3. Industrial application

creates basic innovations.

transfers basic innovations to the application stage and creates prototypical solutions.

implements application-ready solutions in the economy.

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From Idea to Practice : Who stands where?

1. Basic research Universities

Helmholtz Centers Max-Planck-Institutes

2. Application-oriented research Industrial

research centers Fraunhofer Institutes

3. Industrial application Companies

creates basic innovations.

transfers basic innovations to the application stage and creates prototypical solutions.

implements application-ready solutions in the economy.

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The Fraunhofer-Gesellschaft in Germany

60 Institutes more than 20,000 employees

München

Holzkirchen

Freiburg

Efringen-Kirchen

FreisingStuttgart

PfinztalKarlsruheSaarbrücken

St. IngbertKaiserslautern

DarmstadtWürzburg

Erlangen

Nürnberg

Ilmenau

Schkopau

Teltow

Oberhausen

Duisburg

EuskirchenAachenSt. AugustinSchmallenberg

Dortmund

PotsdamBerlin

Rostock

LübeckItzehoe

Braunschweig

Hannover

Bremen

Bremerhaven

Jena

Leipzig

Chemnitz

Dresden

CottbusMagdeburg

Halle

Fürth

Wachtberg

Ettlingen

Kandern

Oldenburg

Freiberg

Paderborn

Kassel

GießenErfurt

Augsburg

Oberpfaffenhofen

Garching

Straubing

Bayreuth

Bronnbach

Prien

Hamburg

Leuna

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Fraunhofer worldwide

Subsidiary Center

Representative Office Senior Advisor

Project Center / Strategic Cooperation7

PTZ Berlin Two Institutes – One Roof

Fraunhofer IPK:Application-oriented research

IWF of the TU Berlin:Fundamental research

PTZ Berlin Two Institutes – One Roof

Automation

Technology

Virtual Product

Creation

Corporate Management

Production Systems

Medical Technology

Assembly Technology and

Factory Management

Industrial Automation

Technology

Machine Tools and

Manufacturing Technology

Industrial Information

Technology

Quality Science

Joining and Coating

Technology

Quality Management

Joining and Coating

Technology

PTZ Berlin Two Institutes – For The Entire Manufacturing Process Chain

Managing

companies

Developing products

…with innovative

manufacturing technologies,

…and automated

methods

Guaranteeing quality

Manufacturing products…

Automation

Technology

Virtual Product

Creation

Corporate

Management

Production Systems

Assembly Technology and

Factory Management

Industrial Automation

Technology

Machine Tools and Manu-

facturing Technology

Industrial Information

Technology

Quality Science

Joining and Coating

Technology

Joining and Coating

Technology

Quality Management

…machines and

tools,

Global Trends & Brazilian MarketThe Global Markets Beyond Tomorrow

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Global Trends

Verkürzung und

Dynamisierung der

Produktlebens-zyklen

Globalisierung

Individualität der Märkte

Klimawandel und

Ressourcen-verknappung

LernendeGesellschaft/

Wissens-gesellschaft

DemografischerWandel

Durchdringung mit neuen Technologien

Mobilität

Production and

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Global Trends

Production and

Shortening and

dynamic of the product life cycles

Global Markets

Individuality of the

markets

Climate change and

resource scarcity

Learning Society /

Knowledge Society

Demographic

change

New technology

Mobility

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Brazilian MarketAerospace, Energy, Automotive

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Important sectors of the Brazilian Industry

Oil & Gas Sector, Raw materials

Renewable and Clean Energy

Automotive

Aerospace

© Toyota

© Brasil Maior

© Brasil Maior

© Embraer

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Brazilian Industry Needs

Development of turbo machines

Development of micro and small gas turbines for decentralized CHP plants using renewable energy sources (biomass, waste process)

Efficient tools, kinematics and machining technologies ceramic tools, rope kinematic

Hybrid process robot based systems for milling, positioning of parts, pre treatments

Services, monitoring systems, maintenance concepts

Downsizing, Lightweight Design, emission reduction (CO2), new materials (Flex motor)

© Toyota

© Brasil Maior

© Brasil Maior

© Embraer

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Sustainable ProductionInnovations for your Production Systems

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Sustainability in Production

Future strategies, dimensions of sustainability,major developments

Key technologies for production systems and manufacturing processes

Content

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Content

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»Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs.« (Brundtland Report, Work Commission on Environment and Development: Our Common Future, Oxford, 1987.)

»Sustainability is the concept of a permanent, future proof development of the economic, ecological and social dimension of human existence. These three pillars of sustainability are interdependent and require a long-term balanced coordination.« (Final report of the Enquete Commission of the 13th German Bundestag, printed paper 13/11200, Berlin, 1998.)

The Term »Sustainable Development«

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•Employee satisfaction

•Health

•Minimum social standards

•Safety

•Education

•Human-centered production

Economic Ecological Social

•Life cycle extension of resources

(reuse, low-wear components, modular concepts, availability management)

•Renewable and recycled materials

•Regenerative use of energy

•Resource productivity (materials, energy, supplies, operating resources)

•Technology competence

•Minimizing production costs (fast flawless production,0-failure production process chain reduction, process substitution)

•Versatile production

•Efficient employee assignment

Dimensions of Sustainability

Sustainability in production

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Market growth

Innovation degree

Product & Process

Existing markets New markets

New

Products & processes

Existing

Products & processes

Sustainability in productionStrategies for guaranteeing the future of production

Customer adapted technologies with regard to costs, quality & time

Local business networks

Surviving strategies

Customer/ culture adapted technologies

Global business networks

Expansion strategies

Intelligent technologies

Market leadership

Safety strategies

Novel technologies

Technology leadership

Pioneer strategies

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1900 1950 2000

number of employeesresource

manufacturing timewaste

costs emissionsenergy

time ofproduct development

need of knowledgecustomer proximity

variety of productsproduction safety variety of methods

competitionservice

material variety

localized regionalized internationalized relocalizedglobalized

productivity costs quality environment mutabilityCharacteristic

factorytemporary

business alliances

Combine with

subsidiary company

Production

mass product variety product individual productProduct

customerorientation

Strategy productionorientation

marketingorientation

sustainabilityorientation

hybrid product

business

network

flexibilty

intagratibility

2050

The way to sustainability orientation

Sustainability in production

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Content

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Tools Machines andcomponents

Materials

Manufacturingtechnologies

Process chains

Materials

- Ultra hard materials (ni, ti based)

- Lightweight materials (Mg, Al-alloys, metal foams)

- Composite materials (FRP, CFRP, MMC, reinforced ceramic)

- Sintered materials (metallic, ceramic)

Tools

- Coating technologies

- Innovative cutting tools

- Micro tools

- Holistic view on design, production and inset

Manufacturing technologies

- High speed machining- High performance machining

- Hard machining- Ultra precision and micro machining

- Hybrid technologies- Dry machining- Rapid Prototyping

- und Rapid Tooling

Process chains

Reducing process chains by:- Process substitution-Near-Net-Shape technologies

-Highly integrated production

- Integrated production and process development

Key technologies for a sustainable production

Machines and-components

- Innovative machine components

- Self-optimizing, adaptronic structures

- Magnetofluidicpositioning systems

- Strut and rope kinematics

- Reconfigurable machines

Innovation fields of production technology

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Hybrid processing

Geometry identification

Measuring point

Laser abrasion

100 μm

Micro milling

100 μm

Manufacture of parts

Die-set

High precision-machine tool for combined milling/laser processing

measuring

(geometry)

Spindle II

(milling)

Spindle I

(milling)

scanner, lenses

(laser abrasion)

Combination of micro miller and laser abrasion form construction

Milling processing hardened tool steel with ultra micro grain-Hard metal tools up to nominal diameter 0.2 mm

Nearly meltfree laser abrasion using pulsed laser radiation (puls duration < 15 ps, average power 800 mW)

laser processing of pre-milled structured for shortening process times in comparison to complete processing via laser

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Tensile Strength [MPa] 0,2 % Proof Stress [MPa] Breaking Elongation [%]

IN 718, conventional, T = 20°C [1] 1276 1034 6 - 12IN 718, conventional, T = 650°C [1] 1000 862 6 - 12IN 718, melted, T = 20°C [2] 1295 1110 10 - 13IN 718, melted, T = 650°C [2] 1065 905 10 - 13

Selective Laser Melting – Form-flexible production of turbine blades Advantages

Flexible, additive manufacturing process

Manufacturing and repair of compressor and turbine blades of TiAl6V4,

TiAl6Nb7, INC 718, Hastelloy X , Renè 80 using laser radiation

Potentials in design and functionality by assembling parts layer by layer

Strength of generated structures corresponds to those of cast parts

Reduction of inner density of parts by 90 % and of inertia of rotating

components by 30 % using a lattice structure for high part stiffness

Topics

Processing turbine materials with selective laser melting e.g. René 80

Tailor made adjustment of workpiece properties e.g. density, strengthGenerated blade

[2] Inno-Shape: Laserschmelzen von Nickelbasiswerkstoffen; Aachen, Firmenschrift[1] Special Metalls: INCONEL ® alloy 718, Huntington US, 2007, Firmenschrift

Exposure of partgeometrie

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10 μm

vc = 30 m/min

10 μm

vc = 300 m/min

HSC of Titan-Aluminides

Motivation

Outstanding material properties: low density,

high tensile strenght, high oxidation and

corrosion resistance

Conventional machining induce the

generation of cracks at the workpiece surface

HSC

-Ma

chin

ing

Co

nven

tio

nal M

ach

inin

g o

f TiA

l

Conventional machined TiAl HSC-machined TiAl

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HPC-Machining with ceramic cutting

tools. Source: IPK

Conventional machining of

a Ni-based superalloy. Source: IPK

Performance of ceramic cutting tools

Increase of cutting velocity by factor 50

Increase of the material removal rate by factor 40

Significant reduction of the machining time

Significant reduction in the manufacturing costs

s

Milling of IN718

0

125

250

500

Mach

inin

gT

ime t

h

conventional

(vc = 35 m/min)

HPC

(vc = 600 m/min)

Cutting Speed

High Performance Milling of Ni-Superalloys with ceramic cutting tools

HPC with Indexable Inserts

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Motivation

Transfer potentials of ceramic cutting tools to applications

with tool diameters smaller 16 mm.

Goals

Establishment of a knowledge base for design and use of

monolithic ceramic cutting tools.

Development of prototype tools as innovation impulse for

tool producers and turbine production.

Background

Substantial knowledge in tool design, use of ceramic cutting

tools and their application in industrial environments

Excellent equipment for development, manufacturing and

test of tool under one roof in Production Technology Center

Berlin (PTZ)

Face milling tool made of SiAlON-ceramicSource: IPK


Development of ceramic milling cutters

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First prototype tool with diameter of 25 mm (CerCut) , Source: IPK

Milling cutter with diameter of 4 mm made of whisker-ceramic (TechVolk)Source: IPK


AdvanCer „CerCut“

Fraunhofer internal research project

Manufacturing and test of first prototypes

Identification and syndication of industrial partners

InnoNet „TechVolk“

Public and industrial funded research project:

four research institutes and eight companies

Development of complete process chain:

manufacturing of raw material, grinding of tools,

application with modern machine tools

Industrial Implementation concept

Bilateral projects with gas turbine manufacturers

Machining concept for guide vanes:

strategies und parameters, clamping, machine tool.

Projects and Experiences since 2005

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Industrial Implementation concept

Allowances Accessibility

Part Geometry

Path Planning

Tool Geometries

Spindle Technology

KinematicsClamping and Set-ups

Drives and Dynamics

Machining Strategy Machine Tool Technology

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Comparative investigations with cemented carbide tools

Groove-milling in MAR M247 with full cut and cutting

material adapted parameters

Increase of cutting speed by factor 40

Increase of material removal rate by factor 8

Mat

eria

l Rem

ova

l Rat

e Q

W

1.000

1.500

mm³/min

2.500

500

0

CC Sialon

4

Cutting Material

D [mm]

4z [1]

4ae [mm]

1ap [mm] 0.2

10vc [m/min] 400

0.02fz [mm]

255Qw [mm3 /min] 2.037

MAR M247Material

EmulsionLubricant dry

cutters for comparative investigations:a) cemented carbide; b) Sialon Source: IPK


Benchmark of Cemented Carbide and SiAlON

a) b)

High speed machining with ceramic milling cutters. Source: IPK

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Objectives and Work Packages

Development of a quality management

system for the qualification of tool electrode

suppliers

Optimization of the EDM-machining process

for producing seal slots – reduction of

process time and electrode wear

Guarantee the requirements for machining

results (roughness, cracks, form accuracy and

thermal influenced layer)

Modification of machine-tool for producing

seal slots by application of piezo-actuators

GP 7000 for Airbus A380(Quelle: MTU Aero Engines)

Fabrication of Seal Slots in Turbine Components

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GP 7000 for Airbus A380(Source: MTU Aero Engines)

Fabrication of Seal Slots in Turbine Components

Results

Development of two distinct technologies:

maximum increase of the material removal

rate about 173%

maximum reduction of the machining time

about 54%

maximum reduction of tool electrode wear

about 30%

Implementation of the multi step-technology

All quality requirements to the produced seal

slots have been reached

Implementation and validation of results at the

project partner’s machine tool

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Combined Laser-EDM Machining Center (IPK-ILT)

Manufacturing of cooling holes

Motivation

Development of a flexible hybrid Laser-EDM machining

center for producing boreholes with complex forms

Application

Cooling holes in turbo machinery ,

Injection nozzles in automotive

Results

Reduction of process time about 50 %

Development of a vibration unit through piezoelectric

actuators aiming the improvement of the flushing

conditions

Boreholes Laser (left), Laser+ EDM (right)

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Abrasive Flow Machining

Finishing of complex geometries by

machining with abrasive suspension

cylinder abrasive medium piston

workpieceworkpiece holder

cylinder piston

Applications

Machining of hard materials with SiC or diamond grains

Deburring, edge rounding and polishing

Optimization of surface quality (up to Ra = 0.1 μm)

Improvement of air flow conditions

Process simulation by Discrete Element Method

Turbine Blade and work piece holder for machining with AFMBefore AFM After AFM

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Services of Fraunhofer IPKExample of Projects: factory planning, process chain and technology developments

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Initial situation: 4 manufacturing sites

TAG: gas, steam, water turbines

LMZ: gas, steam, water turbines

Elektrosila: generators

ZTL: blades

Goal:

Green field planning for the production of

gas, steam and water turbines

Optimization concept for TAG and

blades manufacturing site

Power Machines, St. Petersburg, RussiaFactory Planning

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Validation of the

developed rough layout

Layout and capacity

planning

Determination and

optimization of the

material flow

3D – Visualization of the

layout

Evaluation and

improvement of the

ramp-up plan

Siemens Gas Turbine Parts Ltd., Shanghai, Optimization of the manufacturing concept

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„INLINE“ Siemens Gas Turbine Plant, Berlin, Planning of the Blades Manufacturing

Development and Implementation

of manufacturing, organization, IT

and technology concepts

Reduction of the manufacturing

costs by 15%, throughput time

by 40 %

Company-wide implementation of

the technology Roadmap

(Lead factory Berlin)

R&D Partnership

initiation

Figure: Gas Turbine Blade

2nd place in Siemens „Team Award“category

„3i Manufacturing Excellence„ (500 submitted projects)

Analysis and Assessment

Developing Proposals for Implementation

Identification of

Key Innovations

Factory planning Manufacturing Technology

Developing

Rough Concept

Ensuring

Potentials

Specification and

Validation

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Introduction into Technology Road Mapping Approach of IPK

Proceeding in technology road mapping

Detection of relevant technologies

Analysis of technological environment, company and competitors Targets, time horizon and level of detail

Demand analysis and prognosis

Analysis of technology complexes

Potential analysis and prognosis

Scenario analysis

Generation of the road map

Detailed performance requirements Relations of dependencies Date of realization Sufficiency and economy analysis

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mroin Energie und Verkehr


© Fraunhofer

Maintenance, Repair and Overhaul Goods with high investment costs and long product lifecycles Revenues from after-sales (MRO) contracts account for a substantial portion of

the overall profit Low level of scientific background, high research demand on MRO techniques High technological and economical potential

Sectors

Railway

Road AviationAero-engines

Wind energy

Stationary Turbines

Solar energy

Transport Energy

Transfer of the technical expertises to other sectors

MRO in Energy and Transport

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© Fraunhofer

Partner des Innovationsclusters MRO

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© Fraunhofer

Structure and organisation

Goals of the Innovation Cluster: Formation of an internationally renowned, highly component MRO-region in Berlin and

Brandenburg Know-how transfer between the transportation, energy and other sectors Conservation of resources due to the extended service life time enabled by the

deployment of enhanced MRO-strategies and technologies

Funding: industry: 4.200.000 € Berlin and Brandenburg: 6.800.000 € Fraunhofer-Gesellschaft: 4.600.000 €

Research and development on MRO-Topics by the Fraunhofer innovation clusterMRO in 3 years is funded with 15 600 000 €

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© Fraunhofer

Project Forms in the Innovation Cluster MRO

Innovation Cluster are project cluster Financing of projects

Industrial project : Research by order:

Subject defined by and project paid by industrial partners, confidentiality

Transfer project: Definition of contents and work plan by

R&D-partners and industry, mixed funding with different public portion

Initial research: Interdisciplinary subjects, definition by R&D-

partner based on recommendation by industry, public funding, publication of results

Interdisciplinarity

Transfer projects

IndustrialProjects

Initial research

Direct applicability

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© Fraunhofer

Fields of innovation

MRO-Planning and digital assistance

Industrial cleaningCondition monitoring and diagnostics

Repair technologies

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Main costs

Assembling and disassembling

Costs of repair of single parts

Material costs of replaced components

Example moving blade

OEMs allow only one single complete

overhaul

Afterwards replacement of new parts

New part costs approx. 500.000 $ for one set

of 1st HDT rotor stage

Direct operation costs of airlines

Distribution of engine costs

Ru

pp

, MTU

Mai

nte

nan

ce H

ann

ove

r

20 % of the total costs of an airline are MRO-costs. 8 % of operation costs are for the MRO of engines.

Relevance of MRO for Airlines

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Robot based automation of maintenance operations and finishing of turbine blades

DecoatingCleaning

IndicationParameterization

Repair welding

Milling GrindingPolishing

HardeningCutting

Repair process chain

Challenge

Varying conditions of parts and fast response times for lot size 1

Low process safety of particular repair steps due to manual operation

Approach

Providing a complete solution for the entire repair process chain

including technologies

Robot operated processing with functionality of machine tools and

iterative processing up to requested precision

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Initial situation

Disks operate at loads up to 100t at temperatures up to 1000°C.

Cracks of 1/10 mm lead to catastrophic failures of the parts.

Edges of the parts are highly critical geometric elements with strict

constraints regarding form and surface integrity.

Actually mainly manual manufacturing with high qualified staff.

Automated edge preparation will increase due to demands from OEMs.

Milling and brushing using CNC machine tools needs high preparation

efforts and is cost intensive due to high machine costs

Manuel edge preparation

Processing of edges on rotor parts of aero turbines

MTU BLISK (Source MTU)

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Challenges

Find a economic and automated solution to fulfill the requirements

Flexible processes to manufacture different parts

Ability for offline programming

Manufacturing of complete batches without input of worker

Approach

Combination of milling and brushing with pliant tools

Process development for representative features of the turbine parts

Robot based process offers high flexibility at low investment costs

Processing of edges on rotor parts of aero turbines

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Achievements

Realization of a forced controlled machining to achieve high accuracies

Planning of robot configurations under consideration of accessibility,

movement capabilities and stiffness of the robot system and local adaption

of iterative machining plan

Development of milling and grinding technologies for different machining

tasks

Compensation of tool wear in milling operations

Test and implementation of developed processes and technologies at our

customers

Application

Finishing of blades and complex parts using belt grinding and vibratory

finishing

Deburring and chamfering of complex parts

Robot operated milling and grinding for finishing of complex parts

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Fraunhofer IPK in BrazilCooperation Projects

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Fraunhofer IPK in Brazil

Actual Projects from Fraunhofer IPK in Brazil :

Turbine Producer: GMA (Gas Metal Arc) Narrow Gap Welding of Hydro Turbine Casings

PUC Rio/ MCTI: Prototypical Implementation of Intellectual Capital Statements in SME

SENAI: Planning and Development of the National Management of SENAI's Institutes as well as existing and future Innovation Institutes

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Desenvolvimentos recentes para uma produção sustentável -

Recent Developments for a Sustainable Production

Thank youfor

your attention!

Production Technology Centre Berlin

Markus Roehner

Head of Manufacturing Technologies

Fraunhofer Institute

Production Systems and Design Technology IPK

Pascalstrasse 8-9

10587 Berlin

Phone +49 (0)30 / 3 90 06-279

Email [email protected]

Internet www.ipk.fraunhofer.de

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