Desenvolvimentos recentes para uma produção sustentável - Recent Developments for a Sustainable Production Palestrante: Eng. Markus Röhner - Fraunhofer Institute for Production Systems and Design Technology – FhG IPK / Alemanha

1. Production Technology Centre Berlin
Desenvolvimentos recentes
para uma produção sustentável
-
Recent Developments for a
Sustainable Production
Dipl.-Ing Markus Röhner
1

2. Agenda
I Fraunhofer
Production Technology Centre Berlin (PTZ)
I Global Trends
The Global Markets Beyond Tomorrow
I Brazilian Market
Aerospace, Energy, Automotive
I Sustainable Production
Innovations for your Production Systems
I Services of Fraunhofer IPK
Example of Projects
I Fraunhofer IPK in Brazil
Cooperation Projects
I Contact
2

3. Fraunhofer
Production Technology Centre Berlin
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4. The German R&D Innovation Chain
3. Industrial application
implements application-ready
solutions in the economy.
2. Application-oriented research
transfers basic innovations to the
application stage and creates
1. Basic research
prototypical solutions.
creates basic innovations.
4

5. From Idea to Practice : Who stands where?
3. Industrial application
 Companies
implements application-ready
solutions in the economy.
2. Application-oriented research
 Industrial
research centers
 Fraunhofer Institutes
transfers basic innovations to the
application stage and creates
1. Basic research
prototypical solutions.
 Universities
 Helmholtz Centers
 Max-Planck-Institutes
creates basic innovations.
5

6. The Fraunhofer-Gesellschaft
in Germany Itzehoe
Lübeck
Rostock
Bremerhaven Hamburg
Oldenburg Bremen
Hannover Berlin
Potsdam
 60 Institutes Braunschweig
Teltow
Magdeburg
 more than 20,000 employees Paderborn
Cottbus
Oberhausen Halle
Dortmund Schkopau Leipzig
Duisburg Kassel Leuna
Schmallenberg Dresden
St. Augustin Erfurt Jena Freiberg
Aachen Euskirchen Gießen Chemnitz
Wachtberg Ilmenau
Darmstadt Bayreuth
Würzburg
Erlangen
Bronnbach
St. Ingbert
Kaiserslautern Fürth Nürnberg
Saarbrücken Karlsruhe
Pfinztal
Ettlingen
Stuttgart Straubing
Freising
Freiburg Augsburg Garching
München
Oberpfaffenhofen
Kandern Prien
Efringen- Holzkirchen 6
Kirchen

7. Fraunhofer worldwide
Subsidiary Center Project Center / Strategic Cooperation
Representative Office Senior Advisor 7

8. PTZ Berlin
Two Institutes – One Roof
Fraunhofer IPK: IWF of the TU Berlin:
Application-oriented Fundamental research
research

9. PTZ Berlin
Two Institutes – One Roof
Corporate Management Assembly Technology and
Factory Management
Virtual Product Industrial Information
Creation Technology
Production Systems Machine Tools and
Manufacturing Technology
Joining and Coating Joining and Coating
Technology Technology
Automation Industrial Automation
Technology Technology
Quality Management Quality Science
Medical Technology

10. PTZ Berlin
Two Institutes – For The Entire Manufacturing Process Chain
Corporate Managing Assembly Technology and
Management companies Factory Management
Virtual Product Developing products Industrial Information
Creation Manufacturing products… Technology
Production Systems …with innovative Machine Tools and Manu-
manufacturing technologies, facturing Technology
Joining and Coating …machines and Joining and Coating
Technology tools, Technology
Automation …and automated Industrial Automation
Technology methods Technology
Quality Management Guaranteeing quality Quality Science

11. Global Trends & Brazilian Market
The Global Markets Beyond Tomorrow
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12. Global Trends
Verkürzung
und
Dynamisierun
g der
Produktleben
s-zyklen
Individualität
der Märkte
Globalisierun
g
Lernende
Mobilität Gesellschaft/
Wissens-
gesellschaft
Durchdringu
ng mit neuen
Technologien
Klimawandel
© Image. Fraunhofer IPK
und Demografischer
Ressourcen- Wandel Production and
verknappung
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13. Global Trends
Shortening
and
dynamic of
the product
life cycles
Individuality
of the
markets
Global
Markets
Learning
Mobility Society /
Knowledge
Society
New
technology
Climate
© Image. Fraunhofer IPK
change and Demographic
resource change Production and
scarcity
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14. Brazilian Market
Aerospace, Energy, Automotive
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15. Important sectors of the Brazilian Industry
 Oil & Gas Sector, Raw materials
© Brasil Maior
 Renewable and Clean Energy
© Brasil Maior
 Automotive
© Toyota
© Image. Fraunhofer IPK
© Embraer
 Aerospace
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16. Brazilian Industry Needs
 Development of turbo machines
 Development of micro and small gas turbines for
© Brasil Maior decentralized CHP plants using renewable energy
sources (biomass, waste process)
 Efficient tools, kinematics and machining
technologies  ceramic tools, rope kinematic
© Brasil Maior
 Hybrid process  robot based systems for milling,
positioning of parts, pre treatments
 Services, monitoring systems, maintenance
© Toyota
concepts
© Image. Fraunhofer IPK
 Downsizing, Lightweight Design, emission
© Embraer
reduction (CO2), new materials (Flex motor)
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17. Sustainable Production
Innovations for your Production Systems
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18. Content
 Sustainability in Production
 Future strategies, dimensions of sustainability,
major developments
 Key technologies for production systems
and manufacturing processes
© Image. Fraunhofer IPK
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19. Content
 Sustainability in Production
 Future strategies, dimensions of sustainability,
major developments
 Key technologies for production systems
and manufacturing processes
© Image. Fraunhofer IPK
19

20. The Term »Sustainable Development«
 »Sustainable development is development that meets the needs of the present
without compromising the ability of future generations to meet their own needs.«
(Brundtland Report, Work Commission on Environment and Development: Our
Common Future, Oxford, 1987.)
 »Sustainability is the concept of a permanent, future proof development of
the economic, ecological and social dimension of human existence. These
three pillars of sustainability are interdependent and require a long-term
balanced coordination.« (Final report of the Enquete Commission of the 13th
German Bundestag, printed paper 13/11200, Berlin, 1998.)
© Image. Fraunhofer IPK
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21. Sustainability in production
Dimensions of Sustainability
Sustainability in Production
Economic Ecological Social
•Minimizing production costs •Life cycle extension of •Employee satisfaction
(fast flawless production, resources •Health
0-failure production (reuse, low-wear
process chain reduction, components, modular •Minimum social
process substitution) concepts, availability standards
•Versatile production management) •Safety
•Efficient employee •Renewable and recycled •Education
assignment materials
•Human-centered
•Regenerative use of energy production
•Resource productivity
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(materials, energy, supplies, operating resources)
•Technology competence
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22. Sustainability in production
Strategies for guaranteeing the future of production
Innovation degree
Product & Process
 Intelligent technologies  Novel technologies
New  Market leadership  Technology leadership
Products & processes  Safety strategies  Pioneer strategies
 Customer adapted technologies  Customer/ culture adapted
with regard to costs, quality & technologies
Existing time  Global business networks
Products & processes  Local business networks  Expansion strategies
© Image. Fraunhofer IPK
 Surviving strategies
Existing markets New markets Market growth
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23. Sustainability in production
The way to sustainability orientation
Strategy production marketing customer sustainability
orientation orientation orientation orientation
Product mass product variety product individual product hybrid product
Production Combine with temporary business
factory
subsidiary company business alliances network
localized regionalized internationalized globalized relocalized flexibilty
Characteristic productivity costs quality environment mutability intagratibility
costs emissions time of
energy number of employees manufacturing time
resource product development
waste
variety of products
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service variety of methods
production safety customer proximity
material variety competition need of knowledge
1900 1950 2000 2050
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24. Content
 Sustainability in Production
 Future strategies, dimensions of sustainability,
major developments
 Key technologies for production systems
and manufacturing processes
© Image. Fraunhofer IPK
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25. Key technologies for a sustainable production Process chains
Manufacturing
Innovation fields of production technology technologies
Materials
Tools Machines and
components
Machines and Tools Manufacturing
-components Materials
- Coating technologies
- Innovative machine - Ultra hard materials Process chains
technologies - High speed machining
components (ni, ti based) Reducing process
- Innovative cutting - High performance chains by:
- Self-optimizing, machining - Lightweight materials
adaptronic structures tools - Process substitution
- Hard machining (Mg, Al-alloys, metal
- Magnetofluidic - Micro tools foams) - Near-Net-Shape
- Ultra precision and
positioning systems - Holistic view on micro machining - Composite materials technologies
- Strut and rope design, production - Hybrid technologies (FRP, CFRP, MMC, - Highly integrated
reinforced ceramic)
© Image. Fraunhofer IPK
kinematics and inset - Dry machining production
- Reconfigurable - Rapid Prototyping - Sintered materials - Integrated
machines (metallic, ceramic) production and
- und Rapid Tooling process development
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26. Hybrid processing Combination of micro miller and laser
abrasion form construction
Spindle I Spindle II
 Milling processing hardened tool steel with ultra
(milling) (milling)
micro grain-Hard metal tools up to nominal
diameter 0.2 mm
 Nearly meltfree laser abrasion using pulsed laser
radiation (puls duration < 15 ps, average power
High precision- 800 mW)
machine tool for
combined  laser processing of pre-milled structured for
measuring scanner, lenses milling/laser shortening process times in comparison to
(geometry) (laser abrasion) processing complete processing via laser
Micro milling Geometry Laser abrasion Manufacture
identification of parts
© Image. Fraunhofer IPK
100 μm Measuring point 100 μm Die-set
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27. Selective Laser Melting – Form-flexible production of turbine blades
Advantages
 Flexible, additive manufacturing process
 Manufacturing and repair of compressor and turbine blades of TiAl6V4,
TiAl6Nb7, INC 718, Hastelloy X , Renè 80 using laser radiation
Exposure of partgeometrie  Potentials in design and functionality by assembling parts layer by layer
 Strength of generated structures corresponds to those of cast parts
 Reduction of inner density of parts by 90 % and of inertia of rotating
components by 30 % using a lattice structure for high part stiffness
Topics
 Processing turbine materials with selective laser melting e.g. René 80
Generated blade  Tailor made adjustment of workpiece properties e.g. density, strength
Tensile Strength [MPa] 0,2 % Proof Stress [MPa] Breaking Elongation [%]
IN 718, conventional, T = 20°C [1] 1276 1034 6 - 12
IN 718, conventional, T = 650°C [1] 1000 862 6 - 12
IN 718, melted, T = 20°C [2] 1295 1110 10 - 13
IN 718, melted, T = 650°C [2] 1065 905 10 - 13
[1] Special Metalls: INCONEL ® alloy 718, Huntington US, 2007, Firmenschrift [2] Inno-Shape: Laserschmelzen von Nickelbasiswerkstoffen; Aachen, Firmenschrift
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28. HSC of Titan-Aluminides
Motivation
Conventional Machining of TiAl
 Outstanding material properties: low density,
high tensile strenght, high oxidation and
corrosion resistance
 Conventional machining induce the
generation of cracks at the workpiece surface
vc = 30 m/min vc = 300 m/min
HSC-Machining
10 μm 10 μm
Conventional machined TiAl HSC-machined TiAl
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29. High Performance Milling of Ni-Superalloys with ceramic cutting tools
HPC with Indexable Inserts
Performance of ceramic cutting tools
 Increase of cutting velocity by factor 50
 Increase of the material removal rate by factor 40
Conventional machining of
a Ni-based superalloy. Source: IPK  Significant reduction of the machining time
 Significant reduction in the manufacturing costs
Milling of IN718
500
Machining Time th
s
250
125
0
HPC-Machining with ceramic cutting conventional HPC
tools. Source: IPK (vc = 35 m/min) (vc = 600 m/min)
Cutting Speed
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30. High Performance Milling of Ni-Superalloys with ceramic cutting tools
Development of ceramic milling cutters
Motivation
 Transfer potentials of ceramic cutting tools to applications
with tool diameters smaller 16 mm.
Goals
 Establishment of a knowledge base for design and use of
monolithic ceramic cutting tools.
 Development of prototype tools as innovation impulse for
tool producers and turbine production.
Background
 Substantial knowledge in tool design, use of ceramic cutting
tools and their application in industrial environments
 Excellent equipment for development, manufacturing and
Face milling tool made of SiAlON-ceramic test of tool under one roof in Production Technology Center
Source: IPK Berlin (PTZ)
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31. High Performance Milling of Ni-Superalloys with ceramic cutting tools
Projects and Experiences since 2005
AdvanCer „CerCut“
 Fraunhofer internal research project
 Manufacturing and test of first prototypes
First prototype tool with diameter of  Identification and syndication of industrial partners
25 mm (CerCut) , Source: IPK
InnoNet „TechVolk“
 Public and industrial funded research project:
four research institutes and eight companies
 Development of complete process chain:
manufacturing of raw material, grinding of tools,
application with modern machine tools
Industrial Implementation concept
Milling cutter with diameter of 4 mm  Bilateral projects with gas turbine manufacturers
made of whisker-ceramic (TechVolk)
Source: IPK  Machining concept for guide vanes:
strategies und parameters, clamping, machine tool.
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32. High Performance Milling of Ni-Superalloys with ceramic cutting tools
Industrial Implementation concept
Part Geometry
Allowances Accessibility
Machining Strategy Machine Tool Technology
Clamping and Set-ups Kinematics
Tool Geometries Drives and Dynamics
Path Planning Spindle Technology
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33. High Performance Milling of Ni-Superalloys with ceramic cutting tools
Benchmark of Cemented Carbide and SiAlON
 Comparative investigations with cemented carbide tools
 Groove-milling in MAR M247 with full cut and cutting
material adapted parameters
 Increase of cutting speed by factor 40
 Increase of material removal rate by factor 8
High speed machining with ceramic 2.500
Cutting Material CC Sialon
milling cutters. Source: IPK
Material Removal Rate QW
Material MAR M247
mm³/min
Lubricant Emulsion dry
a) b) D [mm] 4
1.500
z [1] 4
ae [mm] 4
1.000
ap [mm] 1 0.2
vc [m/min] 10 400 500
cutters for comparative investigations:
a) cemented carbide; b) Sialon fz [mm] 0.02
Source: IPK Qw [mm3 /min] 255 2.037 0
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34. Fabrication of Seal Slots in Turbine Components
Objectives and Work Packages
 Development of a quality management
system for the qualification of tool electrode
suppliers
 Optimization of the EDM-machining process
for producing seal slots – reduction of
process time and electrode wear
 Guarantee the requirements for machining
results (roughness, cracks, form accuracy and
thermal influenced layer)
 Modification of machine-tool for producing
seal slots by application of piezo-actuators
GP 7000 for Airbus A380
(Quelle: MTU Aero Engines)
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35. Fabrication of Seal Slots in Turbine Components
Results
 Development of two distinct technologies:
 maximum increase of the material removal
rate about 173%
 maximum reduction of the machining time
about 54%
 maximum reduction of tool electrode wear
about 30%
 Implementation of the multi step-technology
 All quality requirements to the produced seal
slots have been reached
 Implementation and validation of results at the
GP 7000 for Airbus A380
(Source: MTU Aero Engines) project partner’s machine tool
35

36. Combined Laser-EDM Machining Center (IPK-ILT)
Manufacturing of cooling holes
Motivation
 Development of a flexible hybrid Laser-EDM machining
center for producing boreholes with complex forms
Application
 Cooling holes in turbo machinery ,
 Injection nozzles in automotive
Results
 Reduction of process time about 50 %
 Development of a vibration unit through piezoelectric
Boreholes Laser (left), Laser+ EDM (right) actuators aiming the improvement of the flushing
conditions
36

37. Abrasive Flow Machining
Finishing of complex geometries by
cylinder piston machining with abrasive suspension
Applications
w orkp iece

w orkpiece
ho lder Machining of hard materials with SiC or diamond grains
 Deburring, edge rounding and polishing
cylinder abrasive me dium piston
 Optimization of surface quality (up to Ra = 0.1 μm)
 Improvement of air flow conditions
 Process simulation by Discrete Element Method
Turbine Blade and work piece holder for machining with AFM
Before AFM After AFM
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38. Services of Fraunhofer IPK
Example of Projects: factory planning,
process chain and technology developments
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39. Power Machines, St. Petersburg, Russia
Factory Planning
Initial situation: 4 manufacturing sites
 TAG: gas, steam, water turbines
 LMZ: gas, steam, water turbines
 Elektrosila: generators
 ZTL: blades
Goal:
 Green field planning for the production of
gas, steam and water turbines
 Optimization concept for TAG and
blades manufacturing site
39

40. Siemens Gas Turbine Parts Ltd., Shanghai,
Optimization of the manufacturing concept
 Validation of the
developed rough layout
 Layout and capacity
planning
 Determination and
optimization of the
material flow
 3D – Visualization of the
layout
 Evaluation and
improvement of the
ramp-up plan
40

41. „INLINE“ Siemens Gas Turbine Plant, Berlin,
Planning of the Blades Manufacturing
 Development and Implementation
Factory planning Manufacturing of manufacturing, organization, IT
Technology and technology concepts
Analysis and Assessment
 Reduction of the manufacturing
Developing Identification of
costs by 15%, throughput time
Rough Concept Key Innovations by 40 %
Specification and Ensuring  Company-wide implementation of
Validation Potentials the technology Roadmap
(Lead factory Berlin)
Developing Proposals for Implementation
 R&D Partnership
initiation
2nd place in Siemens „Team Award“category
„3i Manufacturing Excellence„ (500 submitted projects) Figure: Gas Turbine Blade
41

42. Introduction into Technology Road
Mapping Approach of IPK
Proceeding in technology road mapping
Detection of relevant technologies
 Analysis of technological environment,
company and competitors
 Targets, time horizon and level of detail
Demand analysis and Potential analysis and
prognosis prognosis
 Analysis of technology  Scenario analysis
complexes
Generation of the road map
 Detailed performance requirements
 Relations of dependencies
 Date of realization
 Sufficiency and economy analysis
42

43. mro
in Energie und Verkehr
MRO in Energy and Transport
Maintenance, Repair and Overhaul
 Goods with high investment costs and long product lifecycles
 Revenues from after-sales (MRO) contracts account for a substantial portion of
the overall profit
 Low level of scientific background, high research demand on MRO techniques
 High technological and economical potential
Sectors Transport Energy
Road Aviation Stationary Solar energy
Aero-engines Turbines
Railway Wind energy
Transfer of the technical expertises to other sectors
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© Fraunhofer

44. mro
in Energie und Verkehr
Partner des Innovationsclusters MRO
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© Fraunhofer

45. mro
in Energie und Verkehr
Structure and organisation
Goals of the Innovation Cluster:
 Formation of an internationally renowned, highly component MRO-region in Berlin and
Brandenburg
 Know-how transfer between the transportation, energy and other sectors
 Conservation of resources due to the extended service life time enabled by the
deployment of enhanced MRO-strategies and technologies
Funding:
 industry: 4.200.000 €
 Berlin and Brandenburg: 6.800.000 €
 Fraunhofer-Gesellschaft: 4.600.000 €
Research and development on MRO-Topics by the Fraunhofer innovation cluster
MRO in 3 years is funded with 15 600 000 €
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© Fraunhofer

46. mro
in Energie und Verkehr
Project Forms in the Innovation Cluster MRO
Innovation Cluster are project cluster  Financing of projects
Industrial project :
 Research by order:
Direct applicability
Subject defined by and project paid by
Industrial
industrial partners, confidentiality
Projects
Transfer project:
 Definition of contents and work plan by
Transfer projects
R&D-partners and industry, mixed funding
with different public portion
Initial research Initial research:
 Interdisciplinary subjects, definition by R&D-
Interdisciplinarity
partner based on recommendation by
industry, public funding, publication of
results
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© Fraunhofer

47. mro
in Energie und Verkehr
Fields of innovation
Condition monitoring MRO-Planning and
Industrial cleaning Repair technologies
and diagnostics digital assistance
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© Fraunhofer

48. Relevance of MRO for Airlines
20 % of the total costs of an airline are MRO-costs.
8 % of operation costs are for the MRO of engines.
Main costs
 Assembling and disassembling
Rupp, MTU Maintenance Hannover
 Costs of repair of single parts
Direct operation costs of airlines  Material costs of replaced components
Example moving blade
 OEMs allow only one single complete
overhaul
 Afterwards replacement of new parts
 New part costs approx. 500.000 $ for one set
of 1st HDT rotor stage
Distribution of engine costs
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49. Robot based automation of maintenance operations and
finishing of turbine blades
Challenge
 Varying conditions of parts and fast response times for lot size 1
 Low process safety of particular repair steps due to manual operation
Approach
 Providing a complete solution for the entire repair process chain
including technologies
 Robot operated processing with functionality of machine tools and
iterative processing up to requested precision
Repair process chain
Decoating Indication Cutting Repair Milling Grinding Hardening
Cleaning Parameterization welding Polishing
49

50. Processing of edges on rotor parts of aero turbines
MTU BLISK (Source MTU)
Initial situation
 Disks operate at loads up to 100t at temperatures up to 1000°C.
 Cracks of 1/10 mm lead to catastrophic failures of the parts.
 Edges of the parts are highly critical geometric elements with strict
constraints regarding form and surface integrity.
Manuel edge preparation
 Actually mainly manual manufacturing with high qualified staff.
 Automated edge preparation will increase due to demands from OEMs.
 Milling and brushing using CNC machine tools needs high preparation
efforts and is cost intensive due to high machine costs
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51. Processing of edges on rotor parts of aero turbines
Challenges
 Find a economic and automated solution to fulfill the requirements
 Flexible processes to manufacture different parts
 Ability for offline programming
 Manufacturing of complete batches without input of worker
Approach
 Combination of milling and brushing with pliant tools
 Process development for representative features of the turbine parts
 Robot based process offers high flexibility at low investment costs
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52. Robot operated milling and grinding for finishing of complex parts
Achievements
 Realization of a forced controlled machining to achieve high accuracies
 Planning of robot configurations under consideration of accessibility,
movement capabilities and stiffness of the robot system and local adaption
of iterative machining plan
 Development of milling and grinding technologies for different machining
tasks
 Compensation of tool wear in milling operations
 Test and implementation of developed processes and technologies at our
customers
Application
 Finishing of blades and complex parts using belt grinding and vibratory
finishing
 Deburring and chamfering of complex parts
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53. Fraunhofer IPK in Brazil
Cooperation Projects
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54. Fraunhofer IPK in Brazil
Actual Projects from Fraunhofer IPK in Brazil :
 Turbine Producer: GMA (Gas Metal Arc) Narrow
Gap Welding of Hydro Turbine Casings
 PUC Rio/ MCTI: Prototypical Implementation of
Intellectual Capital Statements in SME
 SENAI: Planning and Development of the
National Management of SENAI's Institutes as
well as existing and future Innovation Institutes
© Image. Fraunhofer IPK
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55. Production Technology Centre Berlin
Thank you
for
your attention!
Desenvolvimentos recentes para uma
produção sustentável -
Recent Developments for a Sustainable
Production
© Image. Fraunhofer IPK

56.  Markus Roehner
 Head of Manufacturing Technologies
Fraunhofer Institute
Production Systems and Design Technology IPK
Pascalstrasse 8-9
10587 Berlin
 Phone +49 (0)30 / 3 90 06-279
 Email markus.roehner@ipk.fraunhofer.de
 Internet www.ipk.fraunhofer.de
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