CORDIS provides links to public deliverables and publications of HORIZON projects.
Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Deliverables
The results consist of the design and manufacturing of a high performance large module for prismatic component machining, using advanced light damped structures (LDS). This new machine will be able to cover a larger part of the market request thanks to its wide working field.
The idea is to apply the study and research carried out within the Vino project to modify an existing prototype in order to increase dynamic performances.
The use of LDS on two main component is foreseen: the X axis (column) and the Z axis (ram). These two components are critical for machine working performance because they are constrained asymmetrically to the machine structure and must withstand unbalanced loads.
- working range: 1600 mm X axis, 1200 mm Y axis, 800 mm Z axis
- maximum rapid feed: around 100 m/min
- Drive system: Linear motors for X,Y,Z axis
- highest acceleration: in the range of 12 15 m/s2
- work thrust: around 6 KN per axis - weight of LDS structures: at least 10-20 % less than the welded steel parts (with damping properties increasing 3-5 fold compared to those of ones).
The new LDS, which will be developed and applied to this demonstrator, must face and cope with crucial issues of manufacturing and assembling and must be strong and stiff enough to guarantee high precision finishing operations. Furthermore, they must fit with guideways and revolving devices, allow the clamping of linear motors and motorspindles and they must withstand the conditions of the working environment.
The final design of the LDS structures (Ram and Column) have been provided. The LDS structural behaviour has been simulated and tested. The achieved results (both numerical and experimental) proved that the target goals for damping increasing and weight reduction have been achieved.
The results consist of the design and manufacturing of a high performance laser cutting machine, using advanced light damped structures (LDS).The machine will be designed to work on:
- the round, rectangular or variable tubular element section with a curvilinear and unplanar axis manufactured in a plastic deformation process;
- dishing elements;
- overt rod section elements.
As tubular profile used as structural elements are assuming a more complex form to simplify their assembly in a subsequent mounting phase, the possibility of carrying out effective and cheap laser cutting work after the plastic deformation process (bending) is the main innovative aspect in curvilinear tubular manufacturing.
On the basis of the above consideration Adige-Sala, is developing a new flexible CNC 5 axis laser cutting machining centre for 3D pipe cutting after the bending process. The principal aims are:
- An operative cost reduction
- Noise emission reduction;
- Machine operator risk reduction;
Adige-Sala furthermore intends to further increase performances of its present 5-axis CNC machine in order to reduce the cycle time of the cutting process and increase, at the same time, accuracy and product quality.
Therefore, a 5-axis laser cutting machine has been redesigned within the framework of the VINO project, making use of innovative material solution and different drive systems for the linear axis.
Key data achieved for the VINO Laser cutting Demonstrator is summarised below.
Axis strokes:
X = 2000 mm;
Y = 600 mm;
Z = 500 mm;
Speed: X, Y = 120 m/min;
Z = 60 m/min;
Acceleration:
X= 13 m/s2 (up to 18 m/s2 for LDS version)
Y= 13 m/s2 (expected, but not tested)
Z= 5 m/s2
Structures:
X Column: New light damped material
Y Slide: Light Tube cage
Z Ram: New light damped material
Drive system:
X Column: Linear motor
Y Slide: Linear motor (not mounted on the demonstrator)
Z Ram: Ball-screw
The final demonstrator with a bonded ram and column and moving X and Z axes has been finalised and tested. The LDS structure has the right strength to support all efforts, but can still be improved in terms of stiffness and in industrialisation in order to reduce the number of primary parts involved. An energy saving was detected, but we did not note any improvement in noise emissions.
We are confident that with a new design of the column (which also involves a new design of the main body of the machine), the right stiffness of all elements can be reached. This was impossible within the framework of the project because an existing part would have had to be substituted (with little or no changes in the body of the machine).
LDS Structures can improve damping performance of mechanical components of milling machines. They can also achieve the same stiffness decreasing the total weight at the same time. This demonstrator is a medium-size milling machine incorporating high damping LDS structures in two of its mobile elements. The demonstrator is a re-design of a well-known milling machine: the EURO 2000.
The present machine is built without LDS structure. The comparison of static characteristics and dynamic performance of the demonstrator with the present machine will provide important information about the suitability of LDS Structures as components of mobile elements of milling machines, specially regarding stiffness and shocks resistance. The economic study on the construction of the EURO 2000 with the new elements will complete the preparatory steps necessary to decide whether to sell this new type of machine. The behaviour of the demonstrator will be the first step towards changing the welded structures of mobile elements of Correa Gantry machines to glued LDS structures.
This results consist of methodologies and procedures to be used to characterise new material (e.g. glues and composite), especially for damping point of view, and to validate Fem model of structures regarding dynamic behaviour of proposed LDS solutions (through numerical-experimental comparison of natural frequencies and amplitude of vibration response).
The requirements for this objectives were an accurate estimation of natural frequencies and a description of the mode shapes using just sufficient detail and accuracy to permit their identification and correlation with those obtained from FEM.
The study involved forced vibration analysis (FRF) assuming a harmonic excitation, involving mass, stiffness, viscous damping and structural damping as matrixes. This problem needed a more complicated FE model than those used in the conventional free vibration calculation. As the required solution needed a definition of the mobility matrix, the first stage was to determine test procedures and an appropriate set of mobility functions by experimental tests.
The second stage was to define the appropriate parameters of the chosen FE model. Theoretical and experimental damping data were then compared to evaluate and review simulation tools. Test based on the proposed method were performed on different kinds of glues and on five LDS samples manufactured by EDERENA.
A customised CAD-FEM system for designing LDSs, has been provided and different items have been analysed in order to ensure that the tool is suitable for the end users:
- Complexity and the wideness of groups and components integrated in mechanical design (and in machine-tool design in particular) asked for a detailed FEM model description so that a good correlation is achieved between theoretically calculated values and experimental ones (stiffness, deformation, modal freq.,.).
- Number of elements and nodes which describe the actual physical model had to be as low as possible in order to reduce calculating time.
- The tool to be developed had to be easy to use for the designers in charge of the structural modelling of mechanical devices.
Therefore, appropriate models for glued joints have been developed, implemented and validated. These models ensure accurate results but the number of nodes in the FEM model remains low so that the time for analysis is similar to standard models. The simulation tool is integrated in MSC/PATRAN (widely spread in mechanical design) in order to improve user-friendliness. As a result, an integrated design environment has been provided that includes high capabilities for LDSs definition and accurate analysis while also making it possible to manage these structures in a time-efficient manner and in a user-friendly environment.
New manufacturing and design methodologies have been developed to facilitate the design of LDSs (Light and damped structures) that fulfil requirements for mechanical industry. Different points have been analysed in order to successfully transfer gluing technologies to machine manufacturing sector. Solutions have been proposed, tested and evaluated in terms of lightness, damping, manufacturing time, geometry precision, price, long term resistance, etc.
Special attention has been paid to design methodology validation (simulation tools validation) and to manufacturing processes. These points will assure reliable designs and will permit that the developed methodologies can be easily implemented and final product will be competitive in terms of costs, manufacturing time, time to market, performances, etc.
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