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www.ehu.es/manufacturing UNIVERSIDAD DEL PAÍS VASCO UPV/EHU University of the Basque Country GROUP: Manufacturing Technologies Escuela Superior de Ingenieros de Bilbao Faculty of Engineering of Bilbao www.ehu.es/manufacturing Eman ta zabal zazu

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www.ehu.es/manufacturing

UNIVERSIDAD DEL PAÍS VASCO UPV/EHU

University of the Basque Country

GROUP: Manufacturing Technologies

Escuela Superior de Ingenieros de BilbaoFaculty of Engineering of Bilbao

www.ehu.es/manufacturing

Eman ta zabal zazu

www.ehu.es/manufacturingContacto www.ehu.es/manufacturing

www.ehu.es/manufacturing

ESCUELA TÉCNICA SUPERIOR DE INGENIERIA DE BILBAO

Universidad del País Vasco

http://www.ingenierosbilbao.com/

Fundada en 1897

www.ehu.es/manufacturing

OUR GROUP: MANUFACTURING

Profesores Doctores

Luis Norberto López de Lacalle MarcaideJosé Antonio Sánchez GalíndezAitzol Lamikiz MentxakaJosé Luis Rodil GonzálezNaiara Ortega Rodriguez

Profesores no Doctores

Soraya Plaza PascualAinhoa Celaya EgüenUnai Bravo SuárezEneko Ukar Arrien

Maestro de Taller Numerario

Eduardo Sasía Boya

Profesores no Doctores colaboradores

Iñigo ElóseguiAitor BeranoaguirreJoseba Albizuri

Personal Investigador

Francisco Javier Campa GómezOlatz Ocerin MeñicaIñigo Pombo RodillaBorja Izquierdo AramburuGorka Urbikain Pelayo

Alumnos Colaboradores

Daniel Holgado RamosEduardo Andrés CañalAsier Fernández ValdiviesoRubén González VinuesaNerea Mouriz IrazabalCarlos Endara MayorgaEduardo Fraga CanalUnai Asla GarcíaOscar Portillo LópezAitor Del Corte MartínezDaniel Ruiz DurántezAnder Zamalloa DíazJanire Bengoechea Aresti

+ 7 researchers in Technological centres, trying to finish Ph.D

Final Project

www.ehu.es/manufacturing

OBJETIVES

- Basic research on manufacturing- Applied research-Industrial collaboration- Collaboration with Technological centers of the

Basque Country:- Fatronik - Robotiker- Ideko - Others: Labein- Tekniker

- Integration of an axis Spain-Basque- Ph.D development - Transfer of knowledge to regular formation

www.ehu.es/manufacturing

THE BASQUE COUNTRY INDUSTRY

• Machine Tool: 90% of Spain production• Automotive: brakes, dies, powertrain, MERCEDES (vans)• Aeronautics:

– Engines ITP SA (Rolls Royce)– Frames: AERNNOVA

• Appliance: washing machines, refrigerators FAGOR• Engineering: structures, space SENER• Wind generators: GAMESA EOLICA• Naval: 2 shipyard• Others: new energies, biotechnology, microtechnology• 27 Technological centresNecessity of new products, New scientific installations (Spallation European source), more precision, new added value processes

www.ehu.es/manufacturingwww.ehu.es/manufacturing

MAIN FACILITIES

Machine-tools

• 5 axes High Speed machining center Ibarmia ZV25 U• 3 axes High-speed machining center, Kondia HS1000• CNC machining center, Kondia B500P• CNC lathe CMZ TBI450• Wire EDM machine ONA-Prima E250• Wire EDM machine ONA-AE 300• Sinking EDM machine ONA-Techno H300• CNC Machining center Kondia K76• Lagun GUM Milling machine• Pinacho S90 VS lathe• Other machines: conventional lathe, conventional

milling machine, surface grinding machine, vertical drilling machine

• Esna mechanical press• Plastic injection machine

www.ehu.es/manufacturingwww.ehu.es/manufacturing

Instrumentation• Kistler 9255-B and 9257B cutting forces

measurement systems• Nikon LAIRD-S270 Infrared camera • OROS 4 channels vibration analysis system• Others: SUNX micrometric displacement

sensors, thermocouples, IR pyrometer, etc.

Metrology Lab• Zeiss 850 CNC (CMM)• Mitutoyo BH-504 CMM• Taylor-Hobson Profilometer-surface measuring

machine• Others: surface finish tester, micrometers,

gages, ...

CAD/CAM and software• Unigraphics NX5• Catia V5 R15• CUTPRO academic license• Thirdwave Advantege academic license• Licenses of software for development: Matlab,

Labview, etc.

MAIN FACILITIES

www.ehu.es/manufacturing

OTHER PARTNERS AND RELATIONSHIPS

Universities At international level: ENSAM Bordeaux (France), ENIT Tarbes(France) and Instituto Politécnico de Monterrey must be highlighted.At national level: Coordinator of the Spanish network R2-TAF, network of Advanced Manufacturing Technologies. The network pretends to be an effective tool for the exchange of ideas and resources between Spanish agents. Moreover, more than 20 industrial companies support the initiative, some of them very important in the Spanish context. The network aims at creating new activities of high impact whose consequences can finally benefit the Spanish society.

Technological CentresA close relationship is kept with the technological centers of the Basque Country. A number of people of the Centres are doing their Ph.D. Thesis in our Department. Special relation is held with Fatronik Foundation , Tekniker Foundation , Ideko Technological Center, and with the Manufacturing processes group of Labein.Our group also takes part in the projects concerning new manufacturing process in the Robotiker Technological Workshop.Our Group is one of the founders of marGUNE, Center for Cooperative Research in High Performance Manufacturing.

Partners and relationship

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Associations and NetworksNetwork of Excellence Innovative Production Machines and Systems, IPROMS founded by the FP6 of the UE.

Watch Tower in Mantys, Thematic Network on Manufacturing, headed by CECIMO, association of European machine tool manufacturers.

Member of the AEROSFIN network, The Pyrenees Interregional Network for Aeronautica manufacturing. The partners are Fatronik, Estia(Bayonne), ENIT (Tarbes), and the Cluster of aeronautical industry of the Basque Country, Hegan.

The members of the group are, as individuals, members of:• SME (Society of Manufacturing Engineers) • ASM (American Society of Materials)• Asociación Española de Ingeniería Mecánica (AEIM) • ASME (American Society of Mechanical Engineering)• Institute of Industrial Engineers (IIE)• Sociedad Española de Ingeniería de Fabricación (SIF)• DAAAM Danube Adria Association for Automation and Manufacturing

Partners and relationship

OTHER PARTNERS AND RELATIONSHIPS

www.ehu.es/manufacturing

TWO IMPORTANT CONTEXTS

CiC marGUNE: Centre for the cooperativeresearch on manufacturing

www.margune.org

Spanish Manufacturing Network R2TAF

http://www.ehu.es/r2taf/

www.ehu.es/manufacturing

MATERIAL REMOVAL PROCESSES

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PROJECTS ORIENTED TO:

• Industrial applications– Aeronautics– Automotive– Machine tool

Machines * process = Added value• Basic techniques

– Modelling– Optimization process: modelling, experiments,

instrumentations, conclusions, – Scientific production : diffusion but a tool for

improvement

Projects under contract with firms, but monitored by the Government

Direct funding from the Government

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AERO ENGINE MATERIALS

(low machinability alloys)

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Titanium alloys: Ti6Al4VSuperalloys: Inconel 718Engine steels: JethetteNow, starting with: gamma TiAl, INCO 753…

Industrial interest and scientific:- Study of industrial cases- Basic research and testing

www.ehu.es/manufacturing

JAM

(JET ASSISTED MACHINING)

RANGO DEPRESIONES.

CAUDAL.

ALTA PRES. < 20 MPa. 10-20 l/min.MUY A.P. 100-380 MPa. 3 l/min.ULTRA A.P. > 380 MPa. 2 l/min.

From pumpnozzle

Vf

Coolant jet

Primaryshear zone

Machined part

Carbide

Fragmented chip1998

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High pressureequipment• Pressure 350 bares.

• Flow 40 l/min.

Vertical lathe

• n 300 rpm.

• Power70 Kw.

• ∅ plate 1.800 mm.

Roughing

• Vc 120-140 m/min.

• ap 2-3 mm.

• f 0.3 mm/rev.

• t 10 min.

Finishing

• Vc 180 m/min.

• ap 0.5 mm.

• f 0.2 mm/rev.

• t 12 min.

Superfinishing

• Vc 200-250 m/min.

• ap 0.2 mm.

• f 0.15 mm/rev.

• t 10 min.

JAM

(JET ASSISTED MACHINING)

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INCONEL 718

Vc (m·min-1) 150, 200, 250, 350, 500, 900

f (mm·rev-1) 0.1, 0.2, 0.3, 0.4

ap (mm) 0.2, 0.35, 0.5, 2

(Vbmax) 0.4

RAMPING

apCapa

endurecida

Tool: ceramics, carbide and PCBN

Cutting conditions and

Cutting strategies

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INCONEL 718 MACHINING

EDAXEDAX

Ni, Cr, FeComponen-tes Inconel

718

Q

QRED CUTTING OF INCONEL 718 ADIABATIC

CONDITIONS

Ceramics tools (alumnina with whiskers of CSi)

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PLASMA ASSISTED MACHINING

Millingcenter

Plasma welding

equipment

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“HIGH PERFORMANCE MACHINING OF SUBCRITICAL THICKNESS PARTS”

±0,2Tolini1,6eini31,53Qini540´HH±0,25Tolini2eini21,02QiniCeramic

±0,2Tolini1,6eini2,28Qini150´HH±0,25Tolini2eini1,52QinicarbideStub vanes

±0,15Tolini1,04eini201,6Qini19,6´HH±0,2Tolini1,3eini134,4QiniCeramic

±0,15Tolini0,32eini18,9Qini10´HH±0,2Tolini0,4eini12,6QinicarbideBride

±0,05Tolini2Faspecto3,675Qini301´HH±0,05Tolini2Faspecto2,45Qinislots

±0,15Tolpos±0,018Tol Diam12,276Qini6´HH±0,15Tolpos±0,018Tol Diam8,184QiniPINS

±0,25Tolpos±0,075Tol Diam12,276Qini26´HH±0,25Tolpos±0,075Tol Diam8,184Qiniholes

±0,15Tolini1,04eini201,6Qini81´HH±0,2Tolini1,3eini134,4QiniCeramic

±0,1Tolini0,32eini18,9Qini53´HH±0,2Tolini0,4eini12,6QinicarbideTurning walls

0,8658Qini6´HH0,577QiniScallops

FeaturesObjetive OPENAERState of the art

PROYECTO OPENAER

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STRUCTURAL COMPONENTS

High speed milling of- Aluminium alloys

- Composites CFRP

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MONOLITHIC STRUCTURES

Diseño Airbus Diseño Boeing

MACHINING

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COMPOSITES IN AIRFRAMES

• 1. Radome: Specialized glass Prepregs. Flexcore®honeycomb

• 2. Landing Gear Doors and Leg Fairings: Glass/carbon Prepregs,honeycomb

• 3. Galley, Wardrobes, Toilets: Fabricated Fibrelampanels

• 4. Partitions: Fibrelam panel materials• 5. Wing to Body Fairing: Carbon/glass/aramid

Prepregs. Honeycombs.• 6. Wing Assembly: (Trailing Edge Shroud Box)

Carbon/glass Prepregs. Nomex® honeycomb.• 7. Flying Control Surfaces : Glass/carbon/aramid

Prepregs. Honeycomb.• 8. Passenger Flooring: Fibrelam panels• 9. Engine Nacelles and Thrust Reversers:

Carbon/glass Prepregs. Nomex® honeycomb.• 10. Pylon Fairings: Carbon/glass Prepregs.• 11. Winglets: Carbon/glass Prepregs• 12. Keel Beam: Carbon Prepregs• 13. Cargo Flooring: Fibrelam panels• 14. Flaptrack Fairings: Carbon/glass Prepregs.• 15. Overhead Storage Bins: Prepregs/fabricated

Fibrelam panels• 16. Ceiling and Side Wall Panels: Glass Prepregs• 17. Airstairs: Fabricated Fibrelam panels

18. Pressure Bulkhead: Carbon Prepregs

19. Vertical Stabilizer: Carbon/glass/aramid Prepregs

20. Rudder: Carbon/glass Prepregs. Honeycomb bonded assembly

21. Horizontal Stabilizer: Carbon/glass Prepregs

22. Elevator: Carbon/glass Prepregs. Honeycomb bonded assembly

23. Tail Cone: Carbon/glass Prepregs

www.ehu.es/manufacturing

MILLING OF CFRP

Trimming of large CFRP Drilling with FATRONIK for MTorres

Problems: Dust , tool wear, vibration, composite damage

Solutions:Tool optimisation:

Carbide gradeCoating (new nanoCo)Cutting conditions

Working with: Kendu, Platit, DyFA, Fatronik

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STABILITY OF MACHINING

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www.ehu.es/manufacturing

AEROEBAKI

PRAXIS

Entorno/Colaboraciones

IndustrialIndustrial

IndustrialIndustrial

IndustrialIndustrial

CientíficaCientífica

CientíficaCientífica

AEROSFIN

SKY-SKINCientíficaCientífica

STABILITY OF MACHINING

www.ehu.es/manufacturing

Thin walls

Global ‘stability lobes diagram’, taking into account the relative displacement between tool and part.

Theoretical Solution: Calculation of the Stability Lobes

Introduction

0º180º

90º

Difference of phaseDifference of phase

Step 1

Step 3

Step 2

Step 4

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www.ehu.es/manufacturingExperimental Validation

CHATTER

CHATTER

STABLE

FORCED VIBRATION

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www.ehu.es/manufacturing

OPTIMIZATION OF ROUGHING

Useful for users and machine manufacturers (redesing)

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MQL- DRY MACHINING

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Output fluid speed 6,4m/s.Simulation MQl, Output flow speed 125m/s.

Sistema MQL Sistema convencional

0.04 ml/min

MQL- DRY MACHINING

Ecological aspects

Technological aspects

Economical aspects

Ecoefficiency

Ecolonomía

Sectors:

Automotive (15% cost)Aeronautics

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MQL(MINIMAL QUANTITY

OF LUBRICANT)

OPTIMIZACIÓN:

Obtención de la introdución optima del fluido en la zona de corte.

Reducción del caudal a valores inferiores a 0,06ml/min, obteniendo desgastes inferiores que con fluidos de corte convecionales.

Type of coolant

VB a 45m VB a 158m

MQL a 0,06ml/min 0,042 0,120

MQL a 0,04 ml/min 0,047 0,142

Emulsion 0,071 0,161

aireaceite

<2µm

www.ehu.es/manufacturing

TRIBOLOGY ASPECTS

Is the maximum temperature in the rake face 300º???? BUL In collaboration with:

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DRILLING OF AUSTENITIC STAINLESS STEELS

0

0,02

0,04

0,06

0,08

0,1

tiempo de mecanizado

des

gas

te d

e fl

anco

Vb

b

(mm

)

304-k 316-k 303-k 316-S

AISI 303,304, and 316

Conditions near-to-dry

High pressure coaxial

Redesing of drilling tools

www.ehu.es/manufacturing

MACHINING OF ADI CASTINGS

Project Manunet ADI-TAPS

WZL Aachen, Huvershorn, UHS, ME Platit, our group

Drilling, Threading, Milling

Typical machinability project:(German type)

Tools (substrate, geometry, coating)

ConditionsSurface integrity

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FIVE-AXIS MILLING

Working with five axes in continuous interpolation

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MACHINING

MODELLING

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2D and 3D SIMULATION WITH FEM

Cutting Speed ( Vc)Feed ( f)

Depth of cut ( doc)Length of cut

Cooling

Now using Thirdwave Advantedge

-As tool for hypothesis and results analysis

- Model developed in Abaqus ExplicitTogether with Tekniker

www.ehu.es/manufacturing

MECHANISTIC MODELLING

Estimation of cutting forces and surface tophography (roughness) in milliseconds

www.ehu.es/manufacturing

( ) ( )( ) ( )( ) ( )⎪

⎪⎨

⋅+=⋅+=⋅+=

db,,tKdSKz,dFdb,,tKdSKz,dF

db,,tKdSKz,dF

nacaea

nrcrer

ntctet

κθΨθκθΨθκθΨθCOEFFICETS TYPESCOEFFICETS TYPES

1. Mean coefficents2.2. BilinearBilinear models3. Ortoghonal to oblicue4. Etc.

MECHANISTIC MODELMECHANISTIC MODEL

• Using empirical laws with specific coefficients

• Coeffiencits for each couple: materailand tool

• Process with high complexitity• In miliseconds, the cutting forces.

λVc

µ

Discreteelement of the

edge

MODEL DEVELOPED

Antecedentes

www.ehu.es/manufacturing

α:15º

Fy

Fz

Fx

α: 30º

Validación

Cutting Cutting conditionsconditions

Cutting speed(m/min): 21.7Feed per tooth (mm/z): 0.05ap (mm): 2ar (mm): 8 (slotting)α= ρ=30º

Cutting Cutting conditionsconditionsCutting speed (m/min): 21.7

Feed per tooth(mm/z): 0.15ap (mm): 1.1ar (mm): 8 (Feed per tooth )α=15ºρ=0º

250 N

-100 N

* El eje X es la proyección del avance en dirección horizontal.

MODEL VALIDATION

Al 7075 T6

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Material:Aluminio 7075-LMaterial de Hta:Metal duro+TiAlNΦ =6 Z=2

Condiciones de corte:Velocidad de corte(r.p.m.): 3000Avance por filo(mm/z): 0.07ap(mm): 1ae(mm): 4

1 revolución

OUR GOAL: FLEXIBLE TOOL

RunRun out out withoutwithout cuttingcuttingDisplacementDisplacement in cuttingin cutting

But the system is flexible:

-Slender tools

-Thin walls

Colaborando con

www.ehu.es/manufacturing

INTEGRATION OF MODELS IN CAM

Cutting Parameter Calculator

Vc, fz, ap, ae

Roughing Toolpath

SemifinishingToolpath

Finishing Toolpath

•Z-level Contouring• Special Strategies

Virtual Machining Simulation

• Collision Detection

Part Design

NEW CAMSCHEME

Validated NC Code

Postprocessing

Cutting Force Calculator

HSM Knowledge

Multimedia support

Use of historicalbackground

CAM

SOFT Roughness

estimation

www.ehu.es/manufacturing

SELECTION OF THE BEST TOOLPATHS

TO MINIMIZE THE CUTTING FORCES

Downmillinga) c)

A. Selection of control points B. Evaluation of cutting force each 15º

C. Selection of minimum forcetoolpath

29

12

23

31

24

2611

25.5 Integrated in UGX

www.ehu.es/manufacturing

www.ehu.es/manufacturing

Hybrid (Low computational)

way

SPECIFIC COEFFICIENTS EXTRATED FROM FEM

MillingMillingexperimentsexperiments

Virtual test: orthogonal cutting

Virtual tests: oblique cutting

ResultingResulting the the K’sK’s

Mechanistic model

Ortho to oblique:Armarego theoryGeometric projections

dSKdbtKdF tentct +=dSKdbtKdF renrcr +=

dSKdbtKdF aenaca +=

Direct (High computational)

way

Advantages:

Dependency on i y de Vc

Dependency of the rake angle

Elimination of experiments

ABAQUS

Advantages:

Dependency on i y de Vc

Dependency of the rake angle

Elimination of experiments

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BURNISHING

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BALL BURNISHING

Technique for a better surface finishingTwo main effects:

- Reduction of the roughness

moulds and dies

- Surface hardening

aeronautic parts

P:20 MPa

==

N: 500 N

28º

dxxyl

R ml

ma ∫=

0)(1

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BALL BURNISHING

Inconel 718 (AMS 5596, 52Ni-19Fe-18Cr-5(Cb+Ta)-3Mo-0.9Ti-0.5Al) Driver: Surface integrity - Residual stresses

www.ehu.es/manufacturing

ROLLING OF TRAIN AXLES

AISI 1045

Driver: Time with maximum roughness

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BALL BURNISHING OF DIES AND MOULDS

Diriver: reduction of manual polishing

pulido_ICM-ICT.avi

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ULTRASONIC ASSISTED TURNING

Effect of ultrasonic vibration:

-Roughness reduction- isotropic-Tool wear

Parameters:

-Direction of vibration-Amplitude

Other processes

-Dressing of girnding wheels-Drilling -Wire calibration

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KINEMATIC ERRORS IN FIVE-AXIS MILLING CENTRES

Error at the Tool tip

- Gantry with two-rotary head

- Three axes with two-axis bed

- On axis in tool and other in bed

Two objetives:

Estimation by Homogenous matrix

Test part and procedures for testing

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UPDATING OF FEM MODELS BY MODAL ANALYSIS

FEM4 → 54,85 HzEMA3 → 58,91 Hz

MAC = 94,5 %

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ELECTRODISCHARGE MACHINING

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Wire Electrical Discharge Machining (WEDM)

From basic knowledge…

• Modeling of wire deformation• Influence on precision of WEDM’ed parts

… to competitive advantage

• Increase of machine precision• Development of new industrial products

Avance del hilo

EDM MACHINES AND PROCESSESEDM MACHINES AND PROCESSES

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WIRE ELECTRICAL DISCHARGE MACHINING (WEDM)

Gear pump oval

Ø3mm

EDM MACHINES AND PROCESSESEDM MACHINES AND PROCESSES

Precision in corner-cutting

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WIRE ELECTRICAL DISCHARGE MACHINING (WEDM)

Precision in taper-cutting: Modeling of wire deformation

- FE Models of wire, including non-linearities:

- Mechanics of contact wire-guide- Plastic behaviour of ‘soft’ wires- Large-deformations- Stress stiffening

- Design of Experiments Models including theinfluence of forces exerted during the EDM process

EDM MACHINES AND PROCESSESEDM MACHINES AND PROCESSES

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NUMERICAL MODELS OF THE EDM PROCESS

Simulation of material removal rate and surface finish

EDM MACHINES AND PROCESSESEDM MACHINES AND PROCESSES

tT

kq

zT

yT

xT G

∂∂⋅=+

∂∂

+∂∂

+∂∂

α1

2

2

2

2

2

2

186.28 µm

1.9901 mm

2.0591 mm

Alpha = 243° Beta = 35°

100

80

60

40

20

0

ij

k

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Application of knowledge to the development of NEW INDUSTRIAL PRODUCTS

• Precision WEDM cutting of LARGE-THICKNESS parts (up to 600mm)International Patent and Ph.D. Thesis

• Technologies of HIGH-SPEED CUTTING in new generation machines

• Precision dies for bar drawing in ADVANCED CERAMIC MATERIALSIndustrial partnership (4 companies)

• Real-time EDM PROCESS MONITORING

Ceramic drawing diein B4C

WEDM’ed Test-part in tool steel (Sverker21). Precision: 9µm per

side, thickness 400mm

Instrumentation andsoftware for WEDM process monitoring

EDM MACHINES AND PROCESSESEDM MACHINES AND PROCESSES

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GRINDING

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Fundamentals of the grinding process: numerical models of thethermal behaviour of the process

• PREDICTION OF THERMAL DAMAGE in ground parts

• Numerical model: ‘at-home’ developed SOFTWARE

• Inclusion of MECHANIS OF CONTACT

• MODEL OPTIMIZATION

• Industrial VALIDATION

Equipment for temperature measurementin industrial grinding operations

GRINDING MACHINES GRINDING MACHINES AND PROCESSESAND PROCESSES

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Tribology of Grinding: EXPERIMENTAL MODELS OF FORCES AND WEAR.

• Measurement of FORCES y FRICTION COEFFICIENT during the process

• Characterisation of wheel surface: EVOLUTION OF WEAR

• EMPIRICAL MODEL OF FORCES as a function of wheel wear

Normal and tangential forces, andfriction coefficient as a function of

wheel wear

µm

0246810121416182022242628303234

34.56 µm

3.0015 mm

2.085 mm

Alpha = 26° Beta = 27°

Fn

Ft

Fn

Ft

Grit wear

Active surface of the wheel

GRINDING MACHINES GRINDING MACHINES AND PROCESSESAND PROCESSES

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Development of new industrial products: ELECTRICAL DISCHARGE DRESSING of superabrasive wheels.

• EXPERIMENTAL STUDY and PROCESS INDUSTRIALISATION

dielectric

Removal of worn grits and loadedmaterial from the active surface of

the wheel using the EDM effect

GRINDING MACHINES GRINDING MACHINES AND PROCESSESAND PROCESSES

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LASER

Working with Diode laser (marGUNE)

And CO2 laser (Robotiker)

www.ehu.es/manufacturingLaser - Plasma www.ehu.es/manufacturing

ADVANCED HIGH STRENGTH STEELS (AHSS) LASER CUTTING

• BACKGROUND: new materials involves process parameters changes.

• OBJECTIVE: Optimize laser cutting process parameters for three different AHSS: DP750, TRIP GXE 450B and DIN EN 10292 (with Zn coating).

• HYPOTESIS: If the cutting parameters maximize the cutting speed, improve the quality of the cuts and minimize the HAZone: Cutting AHSS for body car parts.

• EXPERIMENTAL: Tests on different AHSS with a 2.5 kW CO2 laser. Measurements of the kerf and metallurgical analysis

• RESULTS: Optimum parameters and parameter windows for each material.

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LASER & PLASMAMATERIAL DEPOSITION

• BACKGROUND: High added value parts repairs are highly demanded by tooling and aeronautical parts industries.

• OBJECTIVE: High quality repayments on complex parts using selective metal deposition.

• HYPOTESIS: If the particle flow can be simulated in a laser cladding nozzle, the set of laser parameters can be fitted for a specific nozzle design or a new optimum nozzle design can be calculated.

• EXPERIMENTAL: Tests on DIN 1.2379 tool steel up to 62 HRC. Tests with – plasma and wire feeding techniques (very

economic), – Laser & wire feeding, – laser & powder feeding.

CFD Numerical simulation for nozzle design

Laser - Plasma

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LASER POLISHING

• BACKGROUND: Surface polishing is a highly manual technique. Very expensive and time consuming. Die & Mould industry demands automatic polishing techniques. On the other hand, Rapid Manufacturing Techniques produce low surface quality parts.

• OBJECTIVE: Improve surface finishing of metallic complex surfaces by using a laser source.

• HYPOTESIS: If laser polishing process is reliable and automatic, a laser sintered part can be polished in the same SLS machine in one step, resulting a fully functional and finished part.

• EXPERIMENTAL: Tests on SLS Laserform ST-100 and DIN 1.2344 up to 52 HRC.

• RESULTS: Up to 85% surface roughness reduction.

Stainless steel

Infiltred Bronze

PorosityTest SLS-x50

304 HV (≈30HRC)

142 HV

174 HV

Laser - Plasma

www.ehu.es/manufacturing

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