High Performance Nano-structured Composites for Tooling Industry

Project Information

VibraCoat

Grant agreement ID: 718518

DOI

10.3030/718518

Project closed

EC signature date 24 March 2016

Start date 1 April 2016

End date 30 September 2016

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies – Nanotechnologies

Total cost

€ 71 429,00

EU contribution

€ 50 000,00

Coordinated by

Plasmatrix Materials AB
Sweden

Periodic Reporting for period 1 - VibraCoat (High Performance Nano-structured Composites for Tooling Industry)

Reporting period: 2016-04-01 to 2016-09-30

Summary of the context and overall objectives of the project

Reducing vibration from industrial equipment is one of the most important challenges to eliminate causes that adversely influence production state, working conditions of staff, and job safety. In manufacturing, vibration causes bad product quality, auxiliary costs for rework and repairing of damaged machine’s parts. Plasmatrix Materials’ unique technology has the potential to provide products that control machine tool vibration, ideally suited for manufacturing market segment.
The overall objective for the project is to develop a feasibility model and associated marketing strategy for implementing the solution for removing the vibration problem from industrial products by embedded VibraCoat material.
The proposal focuses on market introduction of the VibraCoat material for the cutting tool holders and shims to prolong the tool life of cutting inserts and considerably improve surface quality and process performance.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The work performed in the project has been distributed in several tasks.

1. Market analysis and new applications of VibraCoat for tooling systems - user acceptance and perspective about VibraCoat tooling systems has been testes, and the market potential, type and size has been established

2. Development of pilot tests for the identified range of tooling systems with VibraCoat - requirements for scaling up the process and the range of VibraCoat tooling systems has been determined.

3. Business plan and marketing strategy development - a fully coasted quantitative estimate of the advantages of VibraCoat Tooling system, as part of establishing its market potential and a planned route to its exploitation and an business plan and marketing strategy for VibraCoat tooling systems was developed.

4. Dissemination and exploitation - a robust dissemination plan for maximum impact among stakeholders, workshops and demonstrations were organized. Direct contact with Swedish and European manufacturers.
The practical investigation in laboratory and in limited industrial trials demonstrated that a cutting insert’s too life is expected to be increased by at least 50%, while surface finish to be improved by 60-70% after an embedded solution with VibraCoat.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The VibraCoat project provides three major breakthroughs:
• VibraCoat material,
• Material Synthesis technology, Deposition and bonding technology,
• VibraCoat tooling systems.

(1) Scientific impact
• Knowledge of quantum mechanics and nano-technology.
• Contribute to the scientific community with new milestones for HiDaMats (high dynamic stiffness materials) development
• Nano size impact on materials’ mechanical properties.

(2) Impact on Users/Market
By using VibraCoat tools customers can significantly reduce the vibration levels in their machines or the machines using their parts. This gives them either a competitive edge which enables them to gain market share and/or enables them to address high-end segments in their market where they can charge a premium and obtain better margins.

AAC-HiPIMS second generation coating system

VibraCoat shim with TiC coating

VibraCoat grooving tools in Cr (right) and Ti (left), and vibration measurement

Tool wear on the rake face of conventional (left) and Vibracoat (right) after 50'

VibraCoat material characterization - adhison test

Part machined at LK Precision AB - stainless steel

Vibration of VibraCoat compared to conventional tool

VibraCoat Tooling system