FFI - Robust Machining
New generations of environmentally friendly and safe vehicles require manufacturing of light weight materials with higher strength and, as a consequence, tougher machining conditions and increased machining robustness. There is a lack of practical and reliable methods and tools to meet these challenges in the automotive industry. The very complex system of machine tool, fixture, cutting tools and the machined part is almost impossible to model without complementary measurements of the real system at the factory floor in full production. New ideas and technologies from KTH, HV, Scania and CE Johansson to improve the dynamic and static behavior are based on model identification, Poincaré map techniques, double ball bar with integrated load capability and tracking laser interferometry. New ideas how to improve knowledge reuse from LTU and Volvo Aero will make it possible to better utilize collected data during the lifecycle of the machine. With these technologies we could possible understand the root causes for stability problems and develop solutions in an industrial environment. A new type of innovative high damping interface (HDI) at KTH has a potential to increase the dynamic stiffness to sustain the required productivity, accuracy and reliability of machining systems. The ModArt project has resulted in a new proposal to model production resources based on STEP AP 214. This model need to be further developed to include parameters for stability and robustness.
What to be done: The new concepts and technologies should be further developed and tested in typical industrial cases. It will be an iterative process where the results from industrial case studies will trigger improvements. To start with, a gear cutting machine at Scania in Södertälje, a 5-axis machining center at Saab, Linköping, a machining center at PTC in Trollhättan and a turning center at Leax Falun in Falun will be studied. Depending on the results, additional case studies may be decided by the project steering group.
For each industrial case study a proposal of industrial test and analyze procedure will be developed. Further on actions and measures will be proposed and implemented to increase the stiffness and robustness of the system. Generic advices and suggestions how to specify stiffness and acceptance test methods for new machine tool systems as well as techniques to reuse manufacturing experiences in several contexts.