EXHIBITIONS
This is calculated using the Monte Carlo simulation method.” In projects of this kind, the Fraunhofer Institute is often assisted by other institutes or spin-offs, but in this case the scientists found the support they needed in-house. “In our institute, we have a department for fibre-reinforced-composite and laser-system technologies”, reports Filippos Tzanetos. “This department has over the course of many years accumulated a lot of can-do competences in the field of dimensioning machine tool components made of fibre- reinforced plastics (FRPs), and provides us with proactive support in the shape of simulation expertise for fibre-reinforced component dimensioning.”
Success assured by synergised competences Support of this kind is
indispensable for solving questions encountered when it comes to using FRP components in plant and machinery construction, since these materials, by virtue of their anisotropic properties, are not often used here. “Up to now, there has been a notable reluctance to use FRPs because in contrast to conventional materials there is no recourse available to existing design and dimensioning standards and therefore it’s not that easy to predict an FRP component’s dynamic behaviour in conjunction with the rest of the machine’s structure,” explains the
Aachen-based scientist. “Mistakes are made, for example, when a component is dimensioned in terms of its mechanical strength in just one axis direction, while ignoring the mechanical strength in the other axis directions. But if we use simulation tools to fine-tune the interrelationship between the FRP component and the machine tool’s own dynamics, nothing can go wrong. So to solve the problem, the requisite competences are brought together in our company within this project.”
Lasering, not bonding Another critical consideration is joining CFRPs to metals. Up to now, an adhesive bonding process has been used, which according to Filippos Tzanetos has four disadvantages:
1. The CFRP surface has to be machined mechanically. This leads to unsteadiness and a weakening of the CFRP’s properties.
2. It guarantees only a low level of mechanical strength (per joint: 10 to 40 megapascal).
3. It is closely dependent on the ambient conditions (e.g. temperature, soiling, chips, cooling lubricant).
4. Bonded joints possess a low resistance to wear.
All these disadvantages are eliminated by a lasering process. But it’s not only the joining technology that MAP’s Branch Manager sees as problematic. “In order to assure precise positioning
and reproducibility accuracies in the machine even in the case of high dynamic response, we scrape off the layers on the linear guides by hand,” says Christoph Tischmann. “It’s now an enormous challenge for us to accomplish this with CFRPs as well.” Despite all these difficulties,
the change-over to CFRP has been worth it, opines the expert with a view to the EMO Hannover. The machine tool manufacturer is thinking about a shared information stand with the Fraunhofer IPT, in order to showcase the advances and procedures involved with this “new material”. “Basically, at the end of this project we aim to be putting a dynamic, high-precision, and above all powerful machine on the market,” explains Christoph Tischmann. “We would like to see it becoming widely accepted in the aerospace sector, particularly.”
EMO Hannover is also inspiring the academic community
The IPT scientist, too, sees collaborative projects like that with MAP Werkzeugmaschinen GmbH as a good option for exploring new paths in a process of mutual feedback with the industrial sector. The project currently ongoing has encouraged the researchers in Aachen to press ahead with industrial partners in the field of CFRPs. Filippos Tzanetos and his colleagues from the academic community will be getting
Profiles Fraunhofer IPT, Aachen
The Fraunhofer IPT develops system solutions for production. We focus on the topics of process technology, production machines, production quality and metrology as well as technology management. Our clients and cooperation partners represent all fields of industry: from aerospace technology to the automotive industry and its suppliers as well as tool and die making companies and the precision mechanics, optics and machine tool industries in particular.
Operating budget in 2016: around 27.9 million euros; employees: 450
MAP Werkzeugmaschinen GmbH, Magdeburg In 1995, MAP was founded by expert staff from the former Fritz Werner Werkzeugmaschinen GmbH. MAP is currently responsible for design, both electrical and mechanical, manufacture, service support and spindle service. Synergetic effects are also created by the firm’s sales partner Lerinc Werkzeugmaschinen & Automation GmbH from Heiligenhaus, which handles both sales and the administrative work involved. The present-day MAP Werkzeugmaschinen GmbH scores highly not only in terms of corporate expertise and professional competence in the above-mentioned fields, but also with its many years of intensive sectoral experience in mechanical engineering and the metal-cutting industry. Which is why it meanwhile possesses a prestigious customer base, not least in the automotive and aerospace sectors. Employees: 16
www.internationalmetaltube.com IMT June 2017 33
further input on comparable material-related questions and on lightweight construction in September at the EMO Hannover.
Author: Nikolaus Fecht, specialist journalist from Gelsenkirchen (9,613 characters incl. blanks)
Your contact persons Fraunhofer Institute for Production Technology IPT Susanne Krause External and internal communication Steinbachstrasse 17 52074 Aachen Germany
Phone +49 241 8904-180
susanne.krause@
ipt.fraunhofer.de www.ipt.fraunhofer.de
MAP Werkzeugmaschinen GmbH Christoph Tischmann Branch Manager Alt Salbke 6 – 10 39122 Magdeburg Germany
Phone +49 391 4080715
c.tischmann@mwa-wzm.de www.map-wzm.de
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