Objetivo
The outcome of the project comprises the main results listed below:
-Development of a new fully hydrostatic machine tool with sub-micron accuracy for hard machining of small components,
-Development of the prototype of a high-precision, in-cycle measuring system with measuring accuracy in the sub-micron range (< 1 µm),
-Development of a prototype force measuring system which is able to monitor tool wear,
-Development of the process technology for the high precision manufacture of bearing and hydraulic components including error compensation strategies,
-Development of finite element based models describing part quality and making it possible to calculate in advance the errors which may be expected from thermal effects of the cutting process,
-Development of dedicated precision tools and tool holders.
Beyond these developments comprehensive machining tests and investigations led to a visible progress in terms of a better understanding of the hard turning technology in several fields. These investigations make it possible to use the systems mentioned above in an optimum manner.
The main working fields were:
-Investigations in machine related errors and their effect on part quality as well as the direct comparison of two different machine tool concepts,
-Investigation in the influence of clamping on part accuracy,
-Capability study and testing of the measuring system for in-cycle measurement which is integrated in a lathe and development and assessment of error correction strategies when using such a system for high precision hard turning,
-Investigations in errors caused by tooling and process by means of comprehensive machining tests, functional tests and analysis by measurement or simulation,
-Investigations in suitable grinding techniques for high-precision cutting edges and investigations in the design requirements of appropriate tool holders,
-Investigation of the use of the FEM-based models for error correction and development of strategies for the improvement of the process layout by the use of these models,
-Functional tests of the behaviour of hard turned surfaces in bearing application (lift off and live time tests) and hydraulic application (sealing tests).By the use of the systems it is possible to increase the level of manufacturing accuracy. Beyond that it is now easier to assess the potential of hard turning for high precision applications.
The levels of part quality currently consistently achieved by hard turning in industrial practice is insufficiently high for many of the fields of application. In areas such as, for example, roller bearing manufacture or the manufacture of components for fuel injection and hydraulic systems, the level of accuracy required is in the range < IT4 (ISO-tolerance class). For this reason, recourse almost always has to be made to grinding and honing processes in serial manufacture. The need to make the manufacturing process more cost effective and environmentally friendly along with the steep increase in the complexity of the components, have made it necessary to develop more flexible and environmentally friendly techniques for the manufacture of precision parts. For this purpose a reliable hard turning process with all its economic and ecological advantages, will be developed in the course of this project. The principle aim of the project is to achieve a sub-micron accuracy level for diameter tolerances of IT3. In order to fulfil this aim the following sub-systems have to be developed:
Development of two different machine tool concepts with sub-micron accuracy for hard machining of steel,
Development of high-precision, in-process monitoring with measuring accuracy in the sub-micron range (< l mm),
Development of process technology for the high precision manufacture of bearing and hydraulic components including error compensation strategies,
Development of mathematical models describing part quality and of a software tool to calculate in advance the errors which may be expected,
Development of dedicated precision tools and tool holders. The project has four principle technological objectives:
Increase in manufacturing flexibility,
Increase the achievable manufacturing quality for hard turning operations from IT6 to IT3 and surface roughness level from Rz = 4 mm down to Rz < I mm mean roughness depth,
Reduce of manufacturing cost by 40%,
Facility to manufacture more complex part geometries thus affording the opportunity for functional integration. The strategic aims of the project are:
Preservation and regaining of workplaces from Asia and the USA in the field of precision manufacturing,
Strengthening of the key industry ,,precision technology" by the increase of market shares,
Reduction of coolant emission by 100% and thus complete elimination of the environmental pollution. Eleven partners from six different countries will participate in this research project. The comprehensive approach required to solve the complex difficulties discussed above is reflected in the interdisciplinarity of the project. The consortium comprises partners from different backgrounds such as metrology, machine tools, tooling and from precision engineering. It combines the scientific competence of European research institutes with the practice-oriented, technical know how of the industry. A primary focus of attention will be to support small and medium sized enterprises, an aim reflected in the fact that 40% of this project will be undertaken by SMEs.
Ámbito científico (EuroSciVoc)
CORDIS clasifica los proyectos con EuroSciVoc, una taxonomía plurilingüe de ámbitos científicos, mediante un proceso semiautomático basado en técnicas de procesamiento del lenguaje natural. Véas: El vocabulario científico europeo..
CORDIS clasifica los proyectos con EuroSciVoc, una taxonomía plurilingüe de ámbitos científicos, mediante un proceso semiautomático basado en técnicas de procesamiento del lenguaje natural. Véas: El vocabulario científico europeo..
- ingeniería y tecnología ingeniería mecánica ingeniería de fabricación fabricación sustractiva
- ciencias naturales ciencias de la tierra y ciencias ambientales conexas ciencias ambientales contaminación
- ciencias naturales matemáticas matemáticas puras geometría
- ingeniería y tecnología ingeniería ambiental energía y combustibles
- ciencias naturales matemáticas matemáticas aplicadas modelo matemático
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Programa(s)
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Programas de financiación plurianuales que definen las prioridades de la UE en materia de investigación e innovación.
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Las convocatorias de propuestas se dividen en temas. Un tema define una materia o área específica para la que los solicitantes pueden presentar propuestas. La descripción de un tema comprende su alcance específico y la repercusión prevista del proyecto financiado.
Convocatoria de propuestas
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Procedimiento para invitar a los solicitantes a presentar propuestas de proyectos con el objetivo de obtener financiación de la UE.
Régimen de financiación
Régimen de financiación (o «Tipo de acción») dentro de un programa con características comunes. Especifica: el alcance de lo que se financia; el porcentaje de reembolso; los criterios específicos de evaluación para optar a la financiación; y el uso de formas simplificadas de costes como los importes a tanto alzado.
Régimen de financiación (o «Tipo de acción») dentro de un programa con características comunes. Especifica: el alcance de lo que se financia; el porcentaje de reembolso; los criterios específicos de evaluación para optar a la financiación; y el uso de formas simplificadas de costes como los importes a tanto alzado.
Coordinador
3439 MT NIEUWEGEIN
Países Bajos
Los costes totales en que ha incurrido esta organización para participar en el proyecto, incluidos los costes directos e indirectos. Este importe es un subconjunto del presupuesto total del proyecto.