Self-Learning Control of Tool Temperature in Cutting Processes


 Organization address address: STRASSE DES 17 JUNI 135
city: BERLIN
postcode: 10623

contact info
Titolo: Ms.
Nome: Simone
Cognome: Ludwig
Email: send email
Telefono: +49 30 314 21371
Fax: +49 30 314 21689

 Nazionalità Coordinatore Germany [DE]
 Sito del progetto
 Totale costo 3˙406˙722 €
 EC contributo 2˙374˙645 €
 Programma FP7-NMP
Specific Programme "Cooperation": Nanosciences, Nanotechnologies, Materials and new Production Technologies
 Code Call FP7-NMP-2008-SMALL-2
 Funding Scheme CP-FP
 Anno di inizio 2009
 Periodo (anno-mese-giorno) 2009-11-01   -   2012-10-31


# participant  country  role  EC contrib. [€] 

 Organization address address: STRASSE DES 17 JUNI 135
city: BERLIN
postcode: 10623

contact info
Titolo: Ms.
Nome: Simone
Cognome: Ludwig
Email: send email
Telefono: +49 30 314 21371
Fax: +49 30 314 21689

DE (BERLIN) coordinator 410˙019.84

 Organization address address: STRADA DELLA PRAIA 12/C
postcode: 10090

contact info
Titolo: Dr.
Nome: Maddalena
Cognome: Rostagno
Email: send email
Telefono: +39 011 9342873
Fax: +39 0119 319 173

IT (BUTTIGLIERA ALTA) participant 397˙649.80

 Organization address address: Kingston Lane
postcode: UB83PH

contact info
Titolo: Ms.
Nome: Teresa
Cognome: Waller
Email: send email
Telefono: 441895000000
Fax: 441895000000

UK (UXBRIDGE) participant 385˙312.00

 Organization address address: Strada Torino 50
postcode: 10043

contact info
Titolo: Dr.
Nome: Massimo
Cognome: Casali
Email: send email
Telefono: +39 011 9083492
Fax: +39 011 9083786

IT (ORBASSANO) participant 288˙824.78

 Organization address address: Exlgasse 20a
city: Innsbruck
postcode: 6020

contact info
Titolo: Dr.
Nome: Detlef
Cognome: Steinmüller
Email: send email
Telefono: +43 512 283559 11
Fax: +43 512 283559 99

AT (Innsbruck) participant 272˙718.00
6    C.F.K. CNC-Fertigungstechnik Kriftel GmbH

 Organization address address: Gutenbergstrasse 8
city: Kriftel
postcode: 65830

contact info
Titolo: Dr.
Nome: Christoph
Cognome: Over
Email: send email
Telefono: +49 241 8906203
Fax: +49 241 8906121

DE (Kriftel) participant 200˙176.00

 Organization address address: VIA BREZZI 26
postcode: 10081

contact info
Titolo: Mr.
Nome: Roberto
Cognome: Mattioda
Email: send email
Telefono: +39 0124 513650
Fax: +39 0124 582050

IT (CASTELLAMONTE) participant 191˙884.55

 Organization address address: "MILL LANE, STANTON FITZWARREN"
postcode: SN6 7SA

contact info
Titolo: Dr.
Nome: Frank
Cognome: Wardle
Email: send email
Telefono: +44 1793 764329

UK (SWINDON) participant 176˙164.00

 Organization address address: ROERMONDERSTRASSE 258A
city: AACHEN
postcode: 52072

contact info
Titolo: Dr.
Nome: Thomas
Cognome: Ebert
Email: send email
Telefono: +49 162 2857888
Fax: +49 3212 1319445

DE (AACHEN) participant 51˙896.00
10    "Profischleif,- Fertigungs- & UmweltTechnik GmbH"

 Organization address address: Giesserweg 5
city: Wernigerode
postcode: 38855

contact info
Titolo: Mr.
Nome: Günther
Cognome: Karle
Email: send email
Telefono: +49 3943 628385
Fax: +49 3943 628111

DE (Wernigerode) participant 0.00


 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

machining    platform    reducing    coolant    device    monitoring    tool    significant    manufacturing    reductions    dry    industry    innovative    combined    capability    time    quality    environment    lubricant    temperature    forces    acoustic    times    contemp    machines    micro    cooling    wear    cutting    linked    sensor    internal    fluid    yet    learning    avoiding    self    workpiece    closed   

 Obiettivo del progetto (Objective)

'The European manufacturing industry is currently facing the challenge of reducing production costs and times while increased product quality. In order to achieve this, the industry must develop new, innovative machining concepts beyond the current state-of-the-art. Current process monitoring systems concentrate on the monitoring of forces, vibrations and acoustic emission as input signals, but do not consider tool temperature. Tool temperature does however have a significant influence on workpiece quality and tool wear and therefore on manufacturing productivity. The ConTemp project will develop a self-learning temperature monitoring system combined with a self-cooling tool. The system will control and stabilise tool temperature in the cutting process, which leads to longer tool lifetimes and increased part accuracies. Significant cost reductions can therefore be achieved, as well as allowing the machining of difficult-to-cut materials without incurring the larger costs typically associated with this. The system is based on the development of a combined sensor/actor system. By using an innovative micro cooling device a closed coolant circuit can be used for the measurement of the tool temperature, and by variation of the coolant flow the temperature can be controlled. A further significant advantage of the system is the possibility of avoiding the need for cooling lubricant. Diamond coatings on the surface of the self-cooling tool will ensure maximumheat dissipation from the tool tip, and so sufficient cooling can be achieved with the interior micro-cooling device to allow dry machining. The avoidance of cooling lubricant will lead to substantial cost reductions and environmentally friendly machining.'

Introduzione (Teaser)

Temperature is a much-neglected yet important parameter in process control. Scientists developed a self-learning temperature sensor and actuator linked to a self-cooling tool for automatic adjustments of tool temperature.

Descrizione progetto (Article)

European manufacturers are pressed to reduce the time and cost of production while increasing product quality. Conventional process monitoring systems evaluate forces, vibration and acoustic emissions. They typically neglect tool temperature, which can significantly affect workpiece quality and tool wear.

in particular, manufacturing new high-temperature alloys and composites imposes high thermal strain on machine tools. Controlling over-heating while avoiding cooling lubricant would save money and protect the environment as well. The EU-funded 'Self-learning control of tool temperature in cutting processes' (Contemp) project was initiated to develop a self-learning temperature monitoring system linked to a tool with self-cooling capability. Integration into existing machines was an important objective.

the self-learning platform for adaptive process control continuously monitors the temperature of the cutting tool, creating a database of optimal process parameters. Monitoring and comparison to previous conditions enables accurate estimation of appropriate process conditions for the current piece. Such capability makes the system particularly useful for small and medium batches in which time-consuming optimisation can end up being a significant percentage of total production time.

A sensor is integrated in the closed internal micro-cooling device. The self-cooling tool system senses temperature data and controls tool temperature based on parameters from the self-learning platform. Its closed nature protects against contamination from the environment, from cooling fluid leaks and from the fluid of dust.

the final design for internal cooling enabled a decrease in tool wear of 25 % compared to wet machining, and more than 230 % when compared to dry machining with coolant temperatures of 20 degrees Celsius. As such, Contemp temperature control technology promises to increase tool lifetime and accuracy while reducing costs and production times. And, better yet, the system can easily be retrofitted to existing machines.

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