1 patented technology gm: mattias rutschinski 1 innovations & ideas rutschinski mattias - face...

1PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 1

INNOVATIONS & IDEASRUTSCHINSKI MATTIAS - Face and CEO BAUER JOACHIM – Tool head and CEO

WHO IS IRUBA INNOVATIONS?

®


- Founded 1. August 2009 -GbR / 2013 -GmbH- Tools are only made at the J. Bauer GmbH - Specials are our specialty (accuracy / design/ form) - IRUBA offers solutions- 2012 start of strong collaboration with DPS (Delcam professional services UK)- 2014 several new Partner to complete solutions

WHO IS IRUBA INNOVATIONS?

®


MANUFACTURING OF FIR-TREE-ROOT NOTCHES

INNOVATIVE GREEN TECHNOLOGY

GERMAN ENGINEERING / PATENT

TOOLS MADE IN GERMANY

CARBIDE MADE IN GERMANY

GERMAN SUPPORT WORLDWIDE

REMANUFACTURING OF TOOL IN GERMANY

®


NEW WAYS

BETTER SOLUTIONSINNOVATIONSNEW TECHNOLOGIES

®


1. 2. 3.

THE IDEA FOR THE NEW TECHNOLOGY

®


BASICS OF THE NEW TECHNOLOGY

A ROUGHING OPERATION- WITH HIGH THERMAL DEVELOPMENT- BIG CUTTING FORCES- LOW CHIP-REMOVAL-RATES

WILL CHANGE INTO A „FINISH OPERATION“- WITH LOWEST THERMAL DEVELOPMENT- LOW CUTTING FORCES - HIGH CHIP REMOVAL RATES

®



Interpolating high performance cutting with only “3“ levels

Special carbide end mill

Low cutting forces, almost no thermal development on the cutting edge

Open the slot -and put in the undercut geometry, will be performed in one single step

®


Interpolating by HPC to manufacture notches on a rotor


Straight notches,Ankle notches,Radius notches,

Alwaysrough-milling without full enlacement

END -MILL FIR -TREE -ROOT NOTCHES

®



Advantages:

1. Highest process safety2. No thermal contribution into boundary layer of work piece

3. Lowest cutting forces (low KW4. Low amount of carbide special tools5. High chip removal rate (Q/min) 6. Short manufacturing time

®

10

PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 10

ADVANTAGES OF THE NEW TECHNOLOGY

This new technology can also be used as a save process to cut super alloys like Inconel or Titanium alloys.

Only necessary change:Parameters, NC program, Adopted tools

®

11


ADVANTAGES OF THE NEW TECHNOLOGY

-With one set of tool for defined geometry, all kinds of notch forms can be machined.

-No limitations!

-Down- cut or up- cut milling operation for the final tool.

-Small distance to the next turbine disc on a rotor will cause no collision trouble due to size of cutting tool

®

12


„STATE OF THE ART TECHNOLOGY“

BROACHING TECHNOLOGY

Classic technology for serial aerospace turbine disk manufacturing

Stationary gas turbines or discs can be manufactured on Multitasking machines (f.ex. WEINGARTNER mpmc).

IRUBA`s solution can easily be applied tomill the fir tree slots in all kind of materials

®

13


BASICS OF THE STANDARD TECHNOLOGY

Present technologies carry often main disadvantages:

1. No save process (full enlacement / Insert-/tool breakage)

2. Damage on work piece and/or spindle

3. Big amount on special tools4. High cutting forces 5. Long manufacturing time6. High total cost of production

®

14


RESULTS OF A REAL TEST WALDRICH COBURG - MULTI TEC

®

15


1. 3.2.

RESULTS OF A REAL TEST

Requirements of the machine:

- Dynamic feed of 2 Axis (X-Y) up to 2000 mm/min on small diameter circulation

- Spindle speed in correlation to diameter of tool max. 5000 Rpm

WALDRICH COBURG - MULTI TEC

®

16


RESULTS OF A REAL TEST Material (EU) : 1.2312Length of Notch : 150,00 mmTotal Depth of Notch: 98,00 mm

1. Step by Carbide Form End -Millae: ~ 2,0 mmap: 36,0 mmte: ~ 3 minQ: ~ 85 cm³/min

2. Step by Carbide Form End -Mill ae: ~ 1,8 mmap: 30,0 mmte: ~ 3 minQ: ~ 45 cm³/min

3. Step by Carbide Form End -Mill ae: ~ 1,5 mmap: 30,0 mmte: ~ 3 minQ: ~ 28 c m³/min

WALDRICH COBURG - MULTI TEC

®

17


PROJECT MANAGEMENT

- „GREEN BUTTON“ TECHNOLOGY CONCEPT- OUTLINE- TESTS- SCHEDULING- IMPLEMENTING

®

18


THE MISSION

®

19


„GREEN BUTTON“ TECHNOLOGY

- Customer will receive:

- Complete new designed serial tool concept- Complete NC -programming of milling path for each geometry - Realistic parameters adjusted for tools, machine and material- Clamping -system with required accuracy and clamping -forces as well with special cooling concept (water based / oil / ATS/Co2)

®

20


AEROSPACE INDUSTRY

- Realistic tests at DPS (DELCAM UK) workshop- Original material of INCONEL 718- Spindle: HSK63A / HSK100A / NEW!: ATS/ CO2 Coolant supply- Advantage: No loss of precious machining time at customers tool shop

®

21


STATIONARY GAS INDUSTRY

- Realistic Tests on MC up to Diam. 1300 and/or max. 3,0 to.- Original Material or similar- Spindle: HSK100- Advantage: No loss of precious Machining time at Customers Tool Shop

®

22


SCHEDULING/ IMPLEMENTING

- DEFINITION OF PROJECT COSTS - ENGINEERING TO GET MANUFACTURING TIME AND PRICING OF TOOLS- CONTRACT - Example at bottom: Slot length:120mm 2 roughing tools, 1 finish tool, Total machining time: 4 min/ slot

®

23


SUMMARIZE OF ADVANTAGES

- According to several different test on big and small machines and due to 5 years of use at the production site at the ABB (CH).

- Customer will save about 30% machining time, compared to fastest

available milling technology- Compared to 800mm disk (Mat. Turbine steel) about same

production time by milling than broaching - Accuracy and surface quality will improve compared to

broaching- Dramatic increase of machine flexibility, new invest of

broaching machine can be saved, deburring and probing on M/C available.

®

24


ADVANTAGES of milling by IRUBA vs. broaching

Setup time per disc /serie 0,5- 1h 5 min max. /Pallet

Setup time new serie 6h – 24h 0,5h

Lead time for broach /tool Up to 8 month Up to 6 weeks

Curved slots Not possible limitless

Deburring Not possible Both sides in one setup

Probing 2. setup/ no measuring Same setup

Roughing + finishing Two setup One setup

Enviroment Oil Water based/ATS/Co 2

Job description broaching center vs. 5 axis miil –turn center

®

25


ADVANTAGES of milling by IRUBA vs. broaching

Footprint in workshop About 150m2 10 – 50m2

Option drilling Not possible No limit

Option turning Not possible No limit

Power Consumtion Up to 100KW 45 -56KW / max. 50%

Flexibility Very limited Very high

Investment 2 – 20 Mio € 300Tsd – 4Mio €

ROI 3 -5 Years 1,5 Years

Cost per hour 150- 350€ 70- 200€

Job description broaching center vs. 5 axis miil –turn center

®

26


THINK ABOUT

- HOW TO CONVINCE FOR PRODUCTS MADE FOR „GREEN TECHNOLOGY “-

BY USING ALMOST 100 YEAR OLD HEAVY POWER CONSUMING MACHINETOOL TECHNOLOGY?

®

27


THINK ABOUT

- FACTS:

- IRUBA TECHNOLOGY REDUCES MORE THAN 50% POWER CONSUMTION BY PRODUCTION SAME WORKPIECE- LESS MACHINING TIME , LOW LEAD TIME OF TOOLS, - HIGHEST FEXIBILITY AT THE PRODUCTION SITE- SMALL „FOOTPRINT“ MACHINES WITH ALMOST DOUBLE PRODUCTIVITY - ALL IN ONE -MILLING / TURNING / DRILLING / IRUBA

„BROACHING“ / DEBURRING / PROBING ON ONE M/C - NEW: INCONEL FIR TREE MILLING WITH ATS/CO2 COOLANT

®

28


THANK YOU

®

1 patented technology gm: mattias rutschinski 1 innovations & ideas rutschinski mattias - face...

Documents

tools11 patented technologygm

tool12 patented technologygm

mattias rutschinski6basics

mattias rutschinski12state

mattias rutschinski5

mattias rutschinski2founded

new technology advantages

mattias rutschinski7