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National Research & Development Plan

2007 - 2013

INNOVATION Program

Evaluation of project no. 1212/2008-2010

Web page of the project: www.mirsand.ro/proiecte.html

TIBB, 06 – 09 octombrie 2010

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PROJECT TITLE: INNOVATIVE TECHNOLOGY AND PROCESSING DEVICES OF THE METALLIC MATERIALS THROUGH FLOWFORMING (DPR)

For the project realization there was formed a partnership out of: SC MIRSAND SRL Brasov, contractor and project coordinator SC MNA PRODCOM IMPEX SRL Bucuresti, partner 1 UNIVERSITATEA “OVIDIUS” Constanta, partner 2.

Project manager:CS dr.ing. Istode Gheorghe-Lucian, SC MIRSAND SRL Brasov

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PRODUCT , TECHNOLOGY OR SERVICE DESCRIPTION

General characteristics :

● Flowforming is a modern technological process that allows modeling of material directed to conduct parts of revolution, cylindrical, conical or ogive, without removing material.

● This technological process is applied in the case of a machine special projected, but can be adapted to a universal processing machine (universal lathe/normal/little cart).Machines specialy projected for the use of this technology are very expensive and this is why they are not widley spread, because they are profitable only for a big series production.During the present project it starts from the adaptation of universal machines to this technology, fact which leads to a big technological flexibility , with manufacturing facts much reduced in comparison to the first case.

● The propsed technology gives the finite products superior qualities , consisting in mechanical characteristics , dimensional precision, exceptional finishing of the surfaces, complex geometries , constructions withou welding.Important is that the semi-product subjected for processig needs to be deformable(low alloy steel, high alloy steel, corrosion proof steel, copper alloy, aluminium alloy etc).

AGENTIA MANAGERIALĂ DE CERCETARE STIINŢIFICĂ, INOVARE SI TRANSFER TEHNOLOGIC – Politehnica

General view of the device and the operating scheme

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AGENTIA MANAGERIALĂ DE CERCETARE STIINŢIFICĂ, INOVARE SI TRANSFER TEHNOLOGIC – Politehnica

Technical characteristics : Range of dimensions (min/max diameter, the length of the pieces at the end depends on the

capability of the processing machine) Example, for a lathe SN 700x4000, Dmax/Dmin/L=230/45/3000 Processing coefficient through FLOWFORMING, m=Dfinal-Dinitial, is established according

to the nature of the material.. Example, for low carbon steels m=0,70-0,75; for aluminium m=0,78-0,85; for copper m=0,70-0,85.

The final thickness of the processed piece can be min. 0,3 mm.

INNOVATIVE ELEMENTS OF THE PROJECT :

• realization of pieces with high complexity, difficult to execute through classical methods;• realization of pieces which enter in subassemblies which define complex systems, impose a high security degree and a very high level of trust in functioning;• high dimensional precision;• dimensional precision and stability in any passed section no matter how thin;• construction without welding for any revolution constructive form( cylindrical ,conic, ogive etc.);• exceptional finishing of the surface;• uniformity and high score of the granular structure;• granular structure direction shaped as helical on the length of the piece;• fracture strength and elasticity improvement for the processed piece;• deformation possibility of deformation of semi-hard materials;• high durability and reliability of the processing tool (roller); doesn’t request sharpening ;• possibility of obtaining profiled shapes with continuum bundle;

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INTELECTUAL PROTECTION OF THE INNOVATION ACTIVITY

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INTELECTUAL PROTECTION OF THE INNOVATION ACTIVITY

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COMPETITIVITY LEVEL OF THE PROJECT’S RESULTS

On the national plan it is less known the fact that by adapting with reduced costs and in short time , the capabilities of a universal processing machine can be extended for the execution of the same pieces with substantially reduced costs, from the material consume and labor point of view and from increasing the performances of the product.

The application of this method ensures economies of aprox. 50% at the material and aprox. 60% at manual labor.

Following the cold straining , the mechanical characteristics of the processed material can grow with 20-90%.

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ECONOMICAL EFFECTS OF THE PROJECTEffects at the producer For the development and implementation of the technology at the two economical agents, it is appreciated an financial effort of T = 2.424.685 lei..

Variant A: For the complete range of products (device +technology +products) it is

estimated a medium price on the market of Ps=103600 lei.Recovered value will be : Vr=T-Ps=2424685-103600=2321085 lei. If from the 10% profit , 7,5% will be destined for the development investment

of the product: p=0,075*103600=7770 lei , it results that the recovering of the similar expenses will be realized after unpacking of n=Vr/p=299 pcs.

At an estimated production of 299 products/year (for the 2 economical agents), results a investment recovering period of D=n/80=299/80=3,7 years.

User effects The main users are IMM and IM holders of universal processing machines .If these

acquire FLOWFORMING devices , along with the necessary technology , they can increase their productivity with 30-50%, concomitant with the reduction of costs with the same percentage.

Reduction of costs at the user takes into consideration the reduction of prime material consume, fabrication time reduction and also the energy and labor consume.

The usage of FLOWFORMING technology has no environmental impact.

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CONCLUSIONS OVER THE PROJECT’S CONTRIBUTION FOR THE ECONOMICAL AGENT

COMPETITIVITY GROWTH

Through the developed activities during this project and the obtained results it has been proved that the innovative ideas used have taken us to the improvement of a technology of processing metallic materials using the existing universal machines and devices, adapted to the manufacturing method.

This technology has been implemented at the project coordinator and is in implementation at the project coordinator partner.

During this project there have been identified more economical agents which are interested in using this technology and to acquire the necessary devices.

AGENTIA MANAGERIALĂ DE CERCETARE STIINŢIFICĂ, INOVARE SI TRANSFER TEHNOLOGIC – Politehnica