Research Insights to a Russian University of ... - TU Graz

Research Insights to a Russian University of Technology

12 September 2019

Prof.,Dr. Andrey KutinVice-rector, Head of Production Engineering InstituteMoscow State University of Technology “STANKIN”

PRODUCTION ENGINEERING GRAZ 2019

Prof. Dr. Tech. Kutin A. MSTU «STANKIN»

Agenda

1. Introduction (General information about TU “STANKIN”).

2. Principles of Research and Development Activity.

3. Advanced Additive Technology Projects.

4. Machine Tool and Cutting Tool Designing.

5. Robotics and CNC Systems

6. Simulation of Manufacturing Systems.

7. Conclusion (Digital Transformation)


1. Introduction (General information about TU

“STANKIN”).








ABOUT STANKIN UNIVERSITY

More than 160 high-

tech equipment units

for educational and

scientific activity

Over 70 corporate

education contracts

with leading industrial

companies

Over 5000 students from 63

countries

Academic staff – 450

Professors, acc.

Professors and teachers

Foreign students - 15% of

total

Double degree

programs with 3

Universities


TU STANKIN EDUCATIONAL ACTIVITY

Mechanical

Engineering

Machine Tools

Material science

Computer

Science and

Engineering

Applied

Informatics

Applied

Mathematics

Photonics, Optical

and Biotechnical

Systems

Mechatronics and

Robotics

Environmental

ManagementCNC - systems

Institute of

Production

Engineering

Institute of

Automation and

Robotics

Institute of

Information

Systems

Institute of

Economics and

Management

Economics and

Management

Management in

Technical Systems

5


TU STANKIN ENGINEERING CENTER - Labs

Metrology Laboratory (precision measurement and monitoring )

Innovative additive technologies and prototyping Laboratory

6



Mechanical processing, EDM and water jet cutting Laboratory

Blank production Laboratory (laser and plasma arc cutting, metal bending andperforating)

7



Metallographic research Laboratory

Nanocoatings and composite materials Laboratory

8


Russian-Swiss Laboratory of micro-cutting

.









The strategic target of scientific activities development

Engineering

Application-orientedresearches

Fundamental

researches

Science

Fundamental and applied research and development in the field of digital engineering and machine tool building in cooperation with leading foreign technical universities, research institutes and companies in the advanced areas of science and technology

The main principles of scientific activities

development

integration of scientific and educational activities

mathematical and computer science base of R&D

implementation of results in industry


Principles of Digital manufacturing


1. 1. Introduction (General information about TU “STANKIN”).








Additive manufacturing methods from engineering thermoplastics

Processes and equipment

Selective Laser

Sintering (SLS)Fused Filament

Fabrication(FFF)

Specimens

Different configurations and filling degree for

bending and tensile tests


Production of complex profile units from CoCrMo by additive manufacturing

methods

Samples of manufactured parts: a - “Nozzle”, b - “Turbine”, c - “Nozzle (version 1)”,

d - “Nozzle (version 2) "


Development of manufacturing processes for wear-resistant composite materials of the WC-Co

system

The original mixture

25% (by weight) WC and

75% (by weight) Co

Material

Mixture of micron powder Co and

nanopowder WC

The structure of the samples obtained by the

SLM method

Processing Parameters:

P = 70 W, V = 30 mm / s.

Cross sectional size of

columnar crystal: 2 μm.

Processing parameters: P = 70

W, V = 300 mm / s.

Cross-sectional size of

columnar crystal: 0.4 μm.


Investigation of the mechanisms of selective laser powder melting

Typical powder particle scatter frames Laser-interaction zone at SLM

Configuration of VIT-2 arc-coating system and the arc type evaporator for

filtering the vapour-ionic flux

LARC® (Lateral Rotating

Cathodes) on a Platit Pi 80

and Platit Pi 311units

Deposition method and equipment

Conception of nano-scale multilayered composite coating (NMCC) for cutting

tools

Preconditions for creation of a composite tool material (wear resistance complex) with a balanced

combination of opposite properties

1. Wear resistance raise, decrease in physical-chemical tools material activity, adapted to interact with the active components of the ionized gas medium (such

as oxygen, nitrogen, carbon)

2. Maintenance of adhesion between AU and WRL, barrier functions (against diffusions, to thermal streams etc.).

3. Maintenance of strong adhesion between WRC and substrate CTM, healing of a carbide substrate surface defects etc.

- AU external layer with nano-sized sublayers (example, TiCrAlN,

Zr-ZrCrAlN, TiCrAlSiN, TiCrAlZrNbN etc.)

- TL transitional ( intermediate) layer with nano sublayers

(example, TiN, ZrN, CrN etc.)

- adhesion underlayer (example, Ti, Zr, Cr, TiN,ZrN, CrN etc.)

- CTM substrate (cemented carbide/HSS/cutting ceramic)

Friction pairs Medical implants Medical instrument

cutting insertsStamping tool

Metal cutting tool

Examples of the use of coating deposition

technologies

Sample Table rotation frequency n, rpm Nanolayer thickness λ, nm Number of

nanolayers

Sample displacement rate Vs,

m/min

Deposition rate Vdep = λ × n

(nm/min)

K1 0.25 302 7 0.3768 75.5

K2 0.5 160 13 0.7536 80

K3 1 70 33 1.5072 70

K4 1.5 53 41 2.2608 79.5

K5 2 38 54 3.0144 76

K6 3 24 85 4.5216 72

K7 5 16 131 7.536 80

K8 7 10 215 10.5504 70

K1 K2 K3 K4 K5 K6 K7 K8

Ability to control the thickness of nanolayers

The crystal structure of coating K1 The crystal structure of coating K7

The crystal structure of coating K8

Creating superlattice nanostructures

Structure of nanolayers in the Zr-ZrN-(Zr,Cr,Al)N coating obtained using TEM

Results of the investigation of the

elemental composition (b, c) and the

crystalline structure (d, e) of the

sample with the Zr-ZrN-(Zr,Cr,Al)N

coating

Complex multicomponent nanostructures








7. Conclusion (Digital Transformation of Manufacturing)

Gear milling CNC machining center


Training hybrid machining center with function of milling and laser sintering


5-axis machining center with a hybrid kinematic structure


Special cutting tools for robotic milling (prototypes)

Uniform-wear cutting edge (concept)

Combined cutting tool (spot drill-countersink-

mill)

‘Compressing’ cutter for robotic milling

(2 teeth)

‘Compressing’ cutter for robotic milling

(5 teeth)

Special design of ball-nose milling cutterStandard ball-nose

milling cutter

Special ball-nose milling cutter with

constant cutting rake angles

Innovative face grooving tool

Base plane

View A

View A

Transformation 1 Transformation 2 Transformation 3


Innovative solid ceramic milling cutter

Both ceramic material and

cutting tool are produced at

MSUT “STANKIN”

32

Design of milling cutter with typesetting inserts used for repairing

railway wheels










Multifunctional robot-medical cell for laser stomatology and maxillofacial surgery

Main functions:

• First: Cutting of soft tissues of gums phantom using a robot with the diode laser by trajectories tasked by surgeon

• Second: Cutting of soft tissues of gums phantom manually using the diode laser with error control by stereo-system data

• Third: Multicriteria evaluation of technological quality of cuts received by robot and surgeon with diode laser

• Fourth: Preliminary simulation that demonstrate for the surgeon his planning trajectories (offline)

• Fifth: Monitoring of medical operation performed by robot and digital indication for safety robotic manipulation under stereo-vision control and a tactile sensing


First function demonstration: Cutting of soft tissues of gums phantom using a robot with the diode laser by trajectories

tasked by surgeonCutting conditions under safety control:

• Laser power

• Speed of robot cutting

• Cutting depth of the fiber tip in the softtissue of the gums

• Cutting width of the fiber tip in the soft tissue of the gums


Second function demonstration: Cutting of soft tissues of gums phantom manually using the diode laser with error control by

stereo-system data

Russian Stereo System produced byGammaMed company, allowing tomeasure the coordinates of thetrajectories performed by the robotand the surgeon.

Surgeon work tool with the diode laser and 3

spherical reflectors, initialized in coordinate system

of stereo-vision


Procedure for quality evaluation of phantom material, that equivalent with the pigs gums

The similarity of the gum phantom material when compared with biological soft tissues is determined primarily by the similarity of incision modes. But, because there are many such modes; it is possible to simplify the task by comparing the static effect of the laser.

a and b - craters on the phantom of the gums

c and d - craters on biological tissue

CNC «AxiOMA Ctrl»

September 2019

www.stankin.ru

«STANKIN» University

Axis

Open

Modular

Architecture

Control

Department: Computer Architecture Control Systems

Parameter Value

Independent

channels

≤ 8

Axes ≤ 32

Interpolating axes

per channel

≤ 16

Spindles per

channel

≤ 4

Gantry groups per

channel

≤ 16

Interpolation cycle 0,1 – 4 ms

Spline interpolation Akima, Cubic

C2, NURBS

NC block preview,

look-ahead

> 300

Industrial field bus Step/Dir, CAN,

EtherCAT,

SERCOS III,

Terminals ≤ 8

39www.ncsystems.ru

Complete solution with NC periphery

Bus couplers with I/O

Power supply modules

Servo drive controllers

Synchronous and

asynchronous servo motors

CNC applications

40

Turning machine with tool wear forecasting integrated in «AxiOMA Ctrl»

Five-axis large machine tool with «AxiOMA Ctrl»

www.stankin.ru

Mini water jet cutting machine tool with «AxiOMA Ctrl»

41www.stankin.ru

CNC applications

Selective laser sintering machine with «AxiOMA Ctrl»

Five-axis water jet cutting machine toolwith «AxiOMA Ctrl»

Five-axis planning and milling machine with

«AxiOMA Ctrl»










43

Nomenclature of products,

procurement and

delivery schedule

Elements of the

technological system

Elements of the

warehouse system

Rules for the movement

of material flows

Work shifts and

work schedule

2D or 3D model

of the logistics system

Reports (statistical data)

The best solution for

the operation of the

manufacturing system

Optimal

parameters of the logistics

system

Input data Output

Elements of transport

systems

Formulation of the problem

Data flow during simulation


"Definition" of the manufacturing system

Structurally:

Reason: Strict restrictions on production areas

In area:

Reason: strict limitations on resources, volatility of scope of work


4

5

When verifying the project for the production, two models of the same manufacturing system were developed using two different tools:

Practically identical simulation results in both cases are achieved

Th

e st

ate

of

pro

du

ctio

n m

od

els

at t

he

mo

men

t t=

35

8,1

4 h

.

DE

LM

IA Q

UE

ST

AN

YL

OG

IC

№

p/p

Calculation

Excel

According to the model in

DELMIA QUEST

According to the model in

AnyLogic

Model of

equipmentКDE m.

Instance of

equipment

Utilization,

% fact.

Instance of

equipmentКDE fact.

1

DMC43VCD 0.696

DMC43VCD_1 69.995 DMC43VCD[0] 0.699

2 DMC43VCD_2 69.744 DMC43VCD[1] 0.696

3 DMC43VCD_3 69.816 DMC43VCD[2] 0.701

4 DMC43VCD_4 69.774 DMC43VCD[3] 0.697

5 DMC43VCD_5 70.361 DMC43VCD[4] 0.701

6 DMC43VCD_6 69.947 DMC43VCD[5] 0.701

7 DMC43VCD_7 69.993 DMC43VCD[6] 0.696

8 DMC43VCD_8 69.745 DMC43VCD[7] 0.699

9 DMC43VCD_9 69.825 DMC43VCD[8] 0.696

10 DMC43VCD_10 69.760 DMC43VCD[9] 0.695

11DMC43VCD_11 69.759 DMC43VCD[10] 0.701

Tools of simulation: practices and comparison of options


4

6









Augmented reality training work with the CNC terminal

48www.ncsystems.ru

Web service interface with aggregated CNC machine data

49www.ncsystems.ru

https://eio.ksu.ru.com/

https://eio.ksu.ru.com/


Logistics

Management of production

processes

Resource management

Monitoring of equipment

Product Lifecycle Management

of the manufacturing system

Product Lifecycle

Management

Automated process control

technological system

Digital twin Digital twin of the

manufacturing system

Design preparation of

production

Technological preparation of

production

Computerized Maintenance

Management System

Enterprise Asset Management

Product Manufacturing

Operation of the product

Planning


Thank you for attention!

Documents

Research Insights to a Russian University of ... - TU Graz