Post on 02-Apr-2020
BHARAT FRITZ WERNER LTD
Bharat Fritz Werner
Approach to Design and Develop Machine Tools Technologies and
Composite Structures
ByDr. Harshad Sonawane
Dr. Kalam Center for Innovation
BHARAT FRITZ WERNER LTD
Bharat Fritz Werner
A Journey Towards Excellence....
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BHARAT FRITZ WERNER LTD
Strong Technical Foundation
1961: Technical and Financial Collaboration with Fritz Werner Werkzeugmaschinen GmbH, Berlin
1970: Partnership with Burckhardt & Weber, Germany
1970-Present: Fully Indian owned company
2012: Acquired Matec Maschinen GmBH
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Over the Past 57 Years in
Machine Tool Industry
BFW’s Leadership Through Continuous and Vigorous “New Product and Technology Development”
Efforts
Market Leader for Seven Consecutive Years in Horizontal & Vertical Machining Centers and Special Purpose
Machines
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Independent
BFW R&D Centerformed in
2014
Dr. Kalam Center for Innovation2016
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Dr. Kalam Center for InnovationFormal Inauguration
February 2016
Formal Inauguration by
Shri. Kiran Kumar
Chairman,
Indian Space Research Organization (ISRO)
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Mission
Basic and Applied Research &Development
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Mission: Human Body Analogy
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Skeleton Muscles Heart Brain Neural network
Health and Performance
*All figures are referred to google.com
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Basic and Applied R&D in Machine Tools
Machine Tool Structures: Skeleton and MusclesHigh Speed Motorized Spindles: HeartThermally Stable Spindles & Machines: BrainCNC Systems and IoT based Management platform: Neural Network
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R&D projects at present
Project # 9001A: Development of Epoxy Granite
Structure BFW + Academia
Project # 9001B: Development of
Composite CI Structure
BFW
Project # 9001:Alternate Materials
for Machine Tool Structures
Project # 9003:Improving thermal
stability of motorized spindles
and complete machine
Project # 9002:Development of high speed high
accuracy motorized spindles
Project #9004:Development of CNC system and
IoT based management
platform
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Project # 9001A:
Design and Development of Epoxy Granite (EGTech) Machine tools
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I: Raw Materials and Equipment
1. Granite slabs
2. Stone crusher
4. Sieve 5. Granite particles
3. Crushed slabs 6. Resin and Hardener
*Photograph courtesy PSG Tech, Coimbatore
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III: Mould Preparation
*Photograph courtesy PSG Tech, Coimbatore
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II: Mixing, Pouring and Compaction
Granite particles
Resin and Hardener Concrete Mixer
Pouring Vibrating table for compaction
Epoxy granite specimens
*Photograph courtesy PSG Tech, Coimbatore
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Mechanical Characterization: Test Setups
Compressive test Split tensile test Flexural test Damping test
Cast Iron (FG 300):960 MPa
Epoxy Granite: 112 MPa
Cast Iron: 300 MPaEpoxy Granite: 28 MPa
Young’s Modulus:
Cast Iron: 135 GPa
Epoxy Granite: 30 GPa
Cast Iron: 0.001
Epoxy granite:0.02
*Photograph courtesy PSG Tech, Coimbatore
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Basic Research of Development of Epoxy Granite is then Applied to
Manufacture VMC Machine Structures
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Cast Iron 3D Model Epoxy Granite 3D Model
Front Back Front Back
VMC Column
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Epoxy granite casting for VMC Column
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Cast Iron 3D Model Epoxy Granite 3D Model
VMC Base
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Epoxy granite casting for VMC Base
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Project # 9001B:
Development of Composite Cast Iron (iCTech) Machine Tools
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Concept
Cast Iron Column prototype
Composite Cast Iron (iCTech) Column
Prototype
Sound/Noise proof
Moisture resistant
Chemical resistant
Stiffness/weight
Excellent damping
Higher service life
Economical
Sustainable
Desired characteristics of iCTech material
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iCTech: Iron Composite Technology*
Special Concrete Variety of Minerals Polymeric Resin and Hardener
Micro-fillers
iCTech Composite*
Surfactants, Wettability agents,
etc…..
*Patented Technology
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Experimental Performance Analysis
Cast Iron block iCTech block
Prototype Samples Preparation
Experimental Setup to measure natural frequencies of vibrations and damping
Impact hammer
Free-free hanging column
Accelerometer Data loggerPC
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Comparison of Concrete with iCTech
(CI Column)
0.3 s
0.25 sec
(Concrete Column)
(iCTech Column)
0.029 s
0.25 s1.2X
improvement
10.3X improvement
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iCTech Composite
Performance Testing for Full Scale VMCMachine
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Stiffness to Weight ratio for iCTechTM Solid Structure: S/W = 12.4Improved by 4 times as compared to existing Cast Iron machines
(S/W=2.9)!
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Appearance of iCTech
VMC machine(unguarded)
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Performance of iCTech BMV 45+ Machine
Existing Unfilled Cast Iron Structures
Base Column Spindle Head
Improved Composite Cast Iron Structures8X Improvement
10X
3X
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Existing Cast Iron VMC Performance: Complete Machine
Radial Immersion Spindle speed: 1000 RPM Feedrate: 800 mm/min
Existing VMC Machine
Machining Noise:
42-46 dB
EN 08 Steel (45 HRc)
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iCTech VMC Performance: Complete Machine
Radial Immersion Spindle speed: 1000 RPM Feedrate: 800 mm/min
Composite Cast Iron VMC Machine
Machining Noise:
32-35 dB
The Machine became 3X Quieter
EN 08 Steel (45 HRc)
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• Upto 5X Vibration Damping & 4X Stiffness
• Upto 3X Longer Tool Life
• Upto 5X Higher Productivity and Surface quality using Stability Lobe
Diagram
• Easy to Machine Harder Materials (60 HRc)
Performance Benefit of iCTechTM Composite Technology
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Project # 9002:
Development of High-Speed High-Accuracy Motorized Spindle
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3D Spindle Layout
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Design Consideration for Building Spindle
• Design of two plane balancing system
• Design of Air Oil lubrication supply to individual bearing
• Spring preload arrangement for bearings
• Effective cooling circuit to reduce thermal deformation
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Motor Rotor
Disc 1 Disc 2
BearingsBearings
Spacers Lock nut Lock nutSpacers
Labyrinth
Dynamic Analysis of Spindle: 3D Model
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First order bending mode at 779 Hz Second order bending mode at 1520 Hz
Twisting mode at 2109 Hz Third order bending mode at 3428Hz
Longitudinal Elongation mode at 3752 Hz Fourth order bending mode at 4460 Hz
Dynamic Analysis of Spindle: FEA
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Project # 9003:
Intelligent Thermal Control of Spindle and Machine
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Ideal spindle Distorted spindle
Background : What is thermal robustness?
Temp. change Thermal distortion of spindle Low accuracy
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Thermal robustness is achieved through three ways: reduction, control and compensation
• Intelligent Real-time Thermal Control (iRTC) module will use all three strategies and will be deployed through iRIS
Three strategies:1. Reduce thermal errors at source2. Thermal error control3. Thermal Compensation
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Thermal error reduction is achieved through a novel Spindle Cooling Module (SCM)
• A novel cooling strategy called SCM is developed• SCM balances the heat dissipation in spindle with the real-
time heat generation • SCM significantly reduces thermal errors
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Novel cooling results upto 50% reduction in thermal error
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Compensation is performed using real-time information
The thermal distortion of a cutting point has got reduced by more than 100% after compensation
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A High-speed Die and Mould Series….For Excellent Performance!
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BFW….A Leader in Innovation!
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BFW….A Leader in Innovation!
BHARAT FRITZ WERNER LTD
Thank You!
Questions?
Reach us:harshad.s@bfw.co.inMob: +91 9341 143 153