Stefan Lender, Invent, DE (Intefix)

Milling of thin walled work pieces
Project: INTEFIX
23rd and 24th of June – Amsterdam

INDEX
1. Problem & Solution
2. INVENT expertise
5. How I4MS helped
3. Results
4. Economical Impact

PROBLEM AND SOLUTION
1. The Industrial issue: Milling of thin walled work pieces
I4MS 2016: FOSTERING DIGITAL INDUSTRIAL INNOVATION IN EUROPE · 23rd and 24th of June · Amsterdam
 Impeller is a part which is difficult to manufacture. The milling of the piece is faced
to the very thin walls and vibration issues.
 Consequences: appearance of vibrations which lead to limited cutting conditions
and poor surface quality
 Solution to improve the machining is to improve the fixture
 Solutions for intelligent fixtures need to be validated within a demonstrator

2. Partners
I4MS 2016: FOSTERING DIGITAL INDUSTRIAL INNOVATION IN EUROPE · 23rd and 24th of June · Amsterdam
 GIGGLE (SME)
End user and Technology provider: Definition of requirements, feedback for real application,
demonstration of the solution.
Development and testing of fixture system, integration of sensory and active clamping
elements, layout and design of fixture system
 C-TEC (SME)
Technology provider: Development of integrated actuator technology for active damping
 TU Dortmund
RTD: Development of process simulation tools for chatter prediction
 OvG University Magdeburg
RTD: Development of monitoring and active damping technology, signal-processing and
control strategies
 INVENT (SME)
Technology provider: Development and testing of integrated piezo-based sensors and CFRP-
elements for passive damping

3. Solutions
I4MS 2016: FOSTERING DIGITAL INDUSTRIAL INNOVATION IN EUROPE · 23rd and 24th of May · Amsterdam
 Solution of intelligent chuck that provides counter excitation
 Process adapted counter excitation reduces vibration
 Complex sensor system to monitor current oscillation pattern
and to provide input data for intelligent chuck
 Results
 Sensor system is integrated in a clamping plate connected to the fixture
 Sensor data analysed by controller to trigger actuators which provide
counter excitation

 Key features of INVENTs sensors: Robust and flexible.
 Sensor features

 INVENT uses research project to combine high-tech products
 Expertise in composite technology and in piezo patch sensor technology
 Sensors integrated in composite parts
 Intelligent structural parts that can detect deformation or vibrations
 The feature can be reused for industrial customers in other application fields
Piezo patch sensor
(standard design)
Flexibility
of sensor
Customized sensor designs
for individual applications
INVENT EXPERTISE
4. Development and production of piezo patch sensors & FRP-composite parts
I4MS 2016: FOSTERING DIGITAL INDUSTRIAL INNOVATION IN EUROPE · 23rd and 24th of June· Amsterdam

 Development of sensor technology to be used for milling chuck
 Adaptation from standard series to INTEFIX application
 Embedded sensor system => New technology
 Resistant to mill chippings, cooling lubricants
 Durable and resistant to impact and vibration
 Suitable for rough industrial environments
 TRIAX sensor plate
 sensor integrated clamping plate => New type of product
 Contribution to INTEFIX
 Design & realisation of several sensor systems within project period
 Delivery of 2 preliminary sensor concepts for experiments
and final version of sensor plate for intelligent chuck
RESULTS
5. TRIAX Sensor plate

 New technology and product line
 Sensor integrated, robust clamping plates for industrial applications
 New market: machining industry (fixtures, chucks, machine components)
 New project opportunities and collaborations established: intelligent
CFRP-components for machines
 How is your current exploitation plan?
 R&D contracts to develop further sensor systems
 In-house manufacture of specific customized sensor systems (small and
medium size series production)
 Business plan:
ECONOMICAL IMPACT
6. For INVENT
Year Turnover (R&D + production) Employees
2016 +1,5% +0
2018 +3,0% +1
2020 +5,5% +2

 Improvement of productivity
 Decrease of manufacturing time
 Less effort for re-work
 Increase in product quality
 Improvement of portfolio
 New business opportunities
 Products with higher complexity
 Products with higher requirements in accuracy
ECONOMICAL IMPACT
7. For GIGGLE

 I4MS provides the platform to perform the project
 Cross-value-chain of new technological developments
 Networking of partners from different branches/industry sectors
 Machining industry / Part manufacturer
 Competence centres / R&D centres / Universities
 Technology providers (CFRP-composites, sensors & actuators, clamping
elements, drives & controler, …)
 Enhanced dissemination opportunities through I4MS
 Incorporation of new partners through an OPENCALL
 Further networking opportunities
 Excellent basis for successful exploitation of results
I4MS
8. How IAMS initiative helped

Stefan Lender, Invent, DE (Intefix)

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