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Dynamic manufacturing of thin-walled work pieces by milling process

Objective

Lightweight components are gaining in importance in EU key industries with good market growth potential (aerospace, automotive, power generation, medical technology etc.). To achieve weight reductions, complex thin-walled structures are combined with high strength materials. However, the lower stiffness of work pieces leads to severe challenges during the milling process:
- Difficulty to achieve high work piece quality, due to vibration and process forces, in industries that have very high safety and quality requirements (aviation, space etc.). Therefore, in many cases manual finishing of the work pieces is required.
- Achievement of acceptable work piece quality only through time and resource consuming trial and error identification of process parameters that circumvent critical process states. This often results in slow and inefficient processes.

To overcome these problems, DynaMill aims at achieving the complete control over the milling process of thin-walled work pieces. This will be realised through a threefold approach combining the development of process planning, adaptive clamping devices and improved cutting conditions. Subsequently, these three developments will be integrated in the DynaMill Technology as a platform. Throughout the project demonstration of intermediate and integrated solutions will play an important role.

The concrete impacts for industry include:
- 30% reduction of production time and costs
- 80% increase in process stability
- 30% reduction of power, compressed air and coolants
- 60% reduction of process set-up time and 70% reduction of wasted raw materials during set-up
- 20% improvement of tool life
- Elimination of finishing operations
As a result the competiveness of European industry will be enhanced significantly.

For the project, a strong consortium consisting of two research institutes, four manufacturers of key technologies (CAM software, machine tools, clamping devices and tools) and four end users has been gathered.

Call for proposal

FP7-2012-NMP-ICT-FoF
See other projects for this call

Funding Scheme

CP-TP - Collaborative Project targeted to a special group (such as SMEs)

Coordinator

FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.
Address
Hansastrasse 27C
80686 Munchen
Germany
Activity type
Research Organisations
EU contribution
€ 984 960,20
Administrative Contact
Andrea Zeumann (Ms.)

Participants (9)

CESKE VYSOKE UCENI TECHNICKE V PRAZE
Czechia
EU contribution
€ 280 079
Address
Jugoslavskych Partyzanu 1580/3
160 00 Praha
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Roman Svabek (Mr.)
STARRAGHECKERT
Switzerland
EU contribution
€ 498 175
Address
Seebleichestrasse 61
9404 Rorschacherberg
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Bernhard Bringmann (Dr.)
MODULE WORKS SRL
Romania
EU contribution
€ 108 600
Address
Strada Logofat Tautu 66 Etaj 1
031214 Bucuresti
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Mariana Abagiu (Ms.)
FRESMAK SA
Spain
EU contribution
€ 298 702,80
Address
Araba Kalea 45
20800 Zarautz
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Ramon Cenarruzabeitia (Mr.)
WALTER AG
Germany
EU contribution
€ 221 400
Address
Derendinger Strasse 53
72072 Tuebingen
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Oliver Braun (Dr.)
GENERAL ELECTRIC (SWITZERLAND) GMBH
Switzerland
EU contribution
€ 190 370
Address
Brown Boveri Strasse 7
5401 Baden
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Andreas Rauch (Mr.)
HEIDELBERG POSTPRESS SLOVENSKO SPOL SRO
Slovakia
EU contribution
€ 221 241
Address
Rybarska 2165/3
91501 Nove Mesto Nad Vahom
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Miroslav Svec (Mr.)
TECHNOPLAST GROUP IPARI KERESKEDELMI ES SZOLGALTATO KFT
Hungary
EU contribution
€ 191 066
Address
Bodva Utca 7
3561 Felsozsolca
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Gabor Zai (Mr.)
LEISTRITZ TURBINENTECHNIK GMBH
Germany
EU contribution
€ 79 805
Address
Lempstrasse 24
42859 Remscheid
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Stefan Altmüller (Dr.)