Machining 4.0 industrial R&D capabilities

Digital twinning and multiscale modelling (simulation-based process development and optimization)

• Machining of metallic and metal matrix composite products
  • Enhance surface integrity
  • Multi-scale simulation
• Machining of thin and large structures
  • Reduction in design-to-manufacturing time and cost
  • Residual stress history
  • Minimization of post-machining distortion
• Machining of fibre-reinforced plastic composite products
  • Elimination of delamination and thermal damage
  • Increase in process productivity
• Computational fluid dynamics analysis of cooling strategies
  • Maximization of cooling efficiency (optimum cooling jet and nozzle design)
  • Improvements to tool life and surface integrity

High-performance robotized machining

• High productivity and part quality for roughing and semi-finishing of large and complex parts using industrial robots
• Robotized additive and subtractive processes
• Cobotic finishing

Hybrid additive/subtractive manufacturing

• Process and strategy development for additive/subtractive products
• Simulation-based optimization to eliminate part distortion
• Machinability of additive manufacturing materials
• 3D net shape complex geometry, hollow features and 3D meshes
• Additive/subtractive repair of parts

Intelligent manufacturing

• Sensor-based monitoring systems
• Advanced real-time signal processing
• AI and machine learning algorithms for real-time monitoring and control
• Tool condition monitoring
• Pre-failure detection
• Part quality monitoring
• Cyber–physical adaptive control
• Closed door manufacturing

Sustainable and hybrid machining

• Minimum quantity lubrication
  • Enhanced machining performance
  • Optimized internal and external delivery
  • Reduced oil consumption and costs
• Cryogenic machining
  • Higher productivity
  • Elimination of part degreasing and easier chip recycling
  • Solution for computer numerical control and robotized machining
• Thermally (laser) assisted machining
  • Improved machining of difficult-to-cut material
  • Enabling machining of super alloys and metallic and metal matrix composites
• Vibration-assisted machining
  • Efficient cutting of hard and composite materials
  • Enhanced part quality and elimination of damage risk
  • Deep hole drilling and machining of super alloys

High-performance super abrasive grinding (SAG)

• Enhancement of SAG process performance
  • Minimization of transient SAG behaviours
  • Maximization of material removal rate, wheel life and ground surface quality
• Simulation-based optimization of SAG
  • High-fidelity grinding simulation capabilities
  • Enabling process design and optimization
• SAG of difficult-to-cut materials
  • Aerospace alloys
  • Hard coatings
  • Metallic and metal matrix composites, carbon fibre reinforced polymers
• Complex and ultra-high precision parts
  • Parts of complex geometries and tight tolerances
  • Difficult-to-cut materials
  • Parts of ultra-high precision

Makino A88E machining centre

• 5-axis, high-speed, high-power horizontal machining centre with dual pallets
• Spindle: maximum speed (18,000 rpm), power (50 KW) and taper (HSK100A)
• Tool magazine capacity: 40 tools
• Maximum workpiece size: Φ (phi) 1000 mm x 1300 mm
• Maximum workpiece weight: 1,200 kg

Integrated technologies

• Intelligent real-time tool condition monitoring and 2-way communication with computer numerical control Fanuc controller
• Minimum quantity lubrication
• Laser-assisted 5-axis milling
• Cryogenic machining
• Vibration-assisted machining
• High-speed spindle attachments (40,000 rpm) for high-speed machining and super abrasive grinding

DMU 100 P duoBLOCK machining centre

• 5-axis, high-speed, high-power horizontal machining centre
• Spindle: maximum speed (18,000 rpm), power (30 KW) and taper (HSK63A)
• Maximum X-axis stroke: 1,000 mm
• Maximum Y-axis stroke: 1,250 mm
• Maximum Z-axis stroke: 1,000 mm
• Maximum workpiece diameter: 1,100 mm
• Maximum workpiece height: 1,600 mm
• Maximum workpiece weight: 2,200 kg

Integrated technologies

• Intelligent real-time process and tool condition monitoring and 2-way communication with computer numerical control Siemens controller
• Cyber–physical real-time adaptive control
• Minimum quantity lubrication
• Cryogenic machining
• Vibration-assisted machining

BOEHRINGER NG 200 turning centre

• 6-axis, 2-spindle turning centre

Integrated technologies

• Intelligent process and tool condition monitoring
• Laser-assisted turning
• Cryogenic turning
• High-pressure cooling
• Precision finishing

High-performance robotic machining

• COMAU high payload NJ-650-2.7 arm
• Siemens 840D controller
• 25 KW spindle, HSK63A taper
• Robot rail and rotating table

High-performance robotic machining

• COMAU high payload NJ-650-2.7 arm
• Siemens 840D controller
• 25 KW spindle, HSK63A taper
• Robot rail and rotating table

Integrated technologies

• Fully automated elastic calibration
• Real-time compensation for path accuracy
• Minimum quantity lubrication

Matsuura LUMEX Avance-25 (hybrid additive/subtractive)

• Metal laser sintering laser powder bed fusion envelope
  • Travel (X/Y/Z): 260/260/100 (mm)
  • Materials: Maraging, SUS630, SUS316L, INCONEL alloy 718
  • Laser type: Ytterbium fibre laser
  • Oscillator output range: 40 W to 400 W
• Integrated high-speed milling
  • Machining spindle speed range: 450 rpm to 45,000 rpm
  • Spindle motor (KW): AC 2.3 / 3.3 (3.0 ~ 4.4 hp)

Integrated robotic wire additive cell 1

Industrial robotic welding cell with the following capabilities and technologies:

• ABB 4400/60 industrial robot
• 5 KW IPG Ytterbium fibre laser 100 μm–200 μm–600 μm with integrated wire and powder feed
• Fronius MIG system with cold metal transfer technology

Integrated robotic welding cell 2

Industrial robotic welding cell with the following capabilities and technologies:

• ABB 4600 robot
• ABB A-500 robot positioner
• Lincoln Electric NERTAMATIC 450 TOPTIG, GTAW and PAW systems
• Huys Industries Limited electro spark deposition system

Direct laser deposition additive CNC machine

• 3 KW TRUMPF TruDiode fibred diode laser
• Reis–LaserTech Modular AM Optics with integrated wire and powder feed
• 6-axis CNC TRUMPF TLC 1005 with rotary table

IPG YLPP picosecond laser system

• Integrated scanner and an Aerotech ECO165LM-0400 linear stage and capable of pulse energy up to 25µj

Sciaky (CNC) electron beam welding system

• Electron beam processing centre
• 42 KW to 60 KV gun with tilt
• 6-axis CNC with rotary table and integrated wire feed

Inspection and characterization facilities

• Mitutoyo MACH 806: coordinate measuring machine (CMM) with multi-axis probes and 0.1 µm resolution
• Microscopy facility (Olympus, Keyence, Struers DuraScan): Olympus GX71 inverted microscope, Olympus BX51 upright microscope, Olympus SZX12 upright telescope, Keyence VK-X250K
• MTS3000-Restan: automatic system able to measure residual stresses by the hole-drilling strain-gage method
• Form Talysurf Series S4C: surface roughness, profile and topography measurement system