HIPERLAM | High Performance Laser-based Additive Manufacturing
01-11-2016
-31-01-2020
01-11-2016
-31-01-2020
09-01-2015
-31-08-2018
We will generate Objects closer to their nominal shape and thus less material will be removed by subtractive processes, and reduce energy consumption and indirectly CO2 emission
We will generate Objects closer to their nominal shape and thus less material will be removed by subtractive processes.
CAxMan aim at using less material by offering new shape design methods for efficient design of voids and cavities. CAxMan also address the design of better and leaner support structures (use of less material) based analysis addressing thermal stresses and distortions during the additive process.
01-10-2016
-30-09-2019
01-09-2016
-31-08-2019
The COMPOSITION Integrated Information Management System will be a digital automation framework that optimises the manufacturing processes by exploiting existing data, knowledge and tools, integrating them with newly installed cyber physical systems (CPS) and automation software, in order to increase productivity and to allow for dynamic adaptation to changing market requirements. CPS using IoT devices such as wireless sensors nodes (WSN) can be easily retrofitted to existing equipment and infrastructure to gather sensory data and detect anomalies as well as opportunities to improve productivity and cvcle time.
01-09-2015
-31-08-2018
01-01-2015
-31-12-2017
01-01-2015
-31-12-2017
11-01-2015
-31-10-2018
Currently, without any demonstrator running, we did not achieve a reduction of waste.
This KPI can probably only be estimated within ReCaM. Effects to the reduction of waste wight arise through reuse of machines and reduction of erroneous products through automatic production or a strict worker guidance and quality checks.
The reduction of CO2 can only be achieved through a reduction of energy consumption in the context of ReCaM. See above
As the dmonstrators are not running under productive conditions, we could not meassure any data here. Therefore the reduction is currently 0.
01-10-2016
-30-09-2019
01-01-2015
-31-12-2017
12-01-2015
-31-05-2019
10-01-2015
-30-09-2018
01-09-2015
-31-10-2019
01-10-2016
-30-09-2019
01-02-2015
-31-01-2018
10-01-2015
-30-09-2018
10-01-2015
-30-09-2018
01-02-2015
-31-01-2018
01-01-2015
-30-06-2018
11-01-2015
-31-10-2018
11-01-2015
-31-10-2018
01-10-2016
-31-03-2020
The solution provided byZ-Fact0r reduces the number of scrapped parts at different steps of the production process. The use of just the needed amount of raw materials is thus a consequence of applying Z-Fact0r, but it has manifold repercussions, as there is reduction of wear of equipment and tools by doing it right the first time. It also eliminates the duplication of auxiliary materials needed to produce the parts.
The Z-Fact0r platform, and the intensive monitoring of both product and process that accompanies it, has been key for the reduction of defective manufactured parts at the flute grinding process. Should similar solutions be implemented in the rest of machines at NECO premises with a defective rate reduction of around 25%, some 20.000€ could be saved by NECO yearly in the form of raw materials (outside-diameter-grinded High Speed Steel bars), which would instead require to be recycled. Furthermore, if the cutting angle happens to be wrong, the parts cannot be remanufactured and need to be scrapped.
The Z-Fact0r solution contributes to prevent defective parts to be sintered and reduces the number of defects during the machining of sintered parts. Most of the defective, very hard components, cannot be recovered by further machining or by healing operations and must thus be fully scrapped. Besides these recyclable materials there are also losses on the different production steps: from milling, spray drying, pressing, green machining and sintering.
With lesser defective part manufacturing, in the same proportion as HSS (raw material), oil consumption from the grinding machine (used as a coolant and in order to reduce friction between the tool and the part) is reduced, and the abrasive material waste generated from the cutting tool is also reduced, something which comes along with the oil as waste waters. Also, further upstream, the usage of salts for the heat treatment process also diminishes.
The reduction of the defective rate in the flute grinding process is key, due to this part of the manufacturing chain being the one with the higher proportion of scrapped parts. The time working on the reworking of the parts or the manufacturing of new, “extra” ones, inside a certain batch, multiplied by the hourly cost of the machines would be the numerical estimation of the saved energy, which, of course, is proportional to CO2 emissions. However, the flute grinding process is not the process with the most energy consumption, but it is, by far, the heat treatment (which is located upstream and, thus, the reduction of the defective in this particular process where the NECO pilot focuses would also impact on the energy saving of the machines and processes that come before).
Obtaining the part with the right specifications at the first attempt means that the energy consumption will be at its lowest. The confidence Z-Fact0r solution brings also allows us to work with closer tolerances, less excesses of material, and thus less re-working time throughout the production steps.
01-10-2016
-29-02-2020
10-01-2015
-30-09-2018
01-12-2014
-30-11-2017
A reduction of at least 20% of defective parts produced by additive manufacturing by CNC LMD, that mus be discarded.
A reduction of at least 50%of defective repairing by robotic LMD, that must reworked to be repaired again .
02-09-2013
-01-09-2017
01-10-2012
-30-09-2015
X-act delviers advanced robotic systems involving humans and dual arm robots in cooperation, thus advancing the way manufacturing systems perform. Therefore it aims to bring about Products, processes and production systems co-evolution.
01-09-2012
-31-08-2016
01-11-2012
-31-10-2016
Additive Manufacturing replaces the need for wet processes which consume water and pollute the environment