Skolkovo Foundation Resident

RUSSIAN MACHINES

SPECIAL METALWORKING MACHINES

Made in Russia

Skolkovo Foundation Resident

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high-tech machines for metalworking

We are aimed to produce high-tech machinery and appear new russian brand in world machine tool market.

Today we solve the problem of processing parts

made of conductive materials in cases when it is

difficult to do or completely impossible to perform

processing by other methods, including traditional

machining.

We are able to manage with complex issues, even when the best foreign technologies are powerless.

Olga SergeenkoCEO

Business area:

1. R&D in sphere of multi-axis electrochemical machining and ultrasonic

shot peening of metal;

2. design and manufacture of machines based on electrophysical methods of

processing hard-to-machine parts;

3. engineering and metalworking services.

«SEMAT» LLC (tm SEMAT) designs and manufactures electrochemical and electrical discharge machines for metal parts processing along with ultrasonic shot peening machines.

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Our company is a resident of the Skolkovo Innovation Center, whose activities are aimed at contributing successful implementation of innovative technology startups in various sectors of our country economy.

Being a part of Promtech Skolkovo cluster, our company is engaged in research and development of electrochemical equipment for multi-axis electrochemical machining with a rod-shaped electrode tool, and also development and production of ultrasonic shot peening machines with artificial intelligence in the control system.

On the basis of Skolkovo Technopark SEMAT has its own experimental-production area equipped with all necessary resources and facilities.

One of the main company advantages and assets is our professional team that includes highly qualified designers, process and service engineers, as well as experienced specialists in management and sales.

Our strategic vision is development and expansion of electrochemical processing and ultrasonic shot peening technologies in the Russian Federation and all over the world.

The company strives to develop its dealer network and enter foreign markets by starting export sales. The basis for achieving ambitious goals is unique technologies and high competence, supplemented by R&D, patents and high-quality service.

Technologies:

1. electrochemical machining;

2. electrical discharge machining;

3. ultrasonic shot peening.

micromechanics and microelectronicsdies and molds manufacturingpower engineeringweapons manufacturingadditive technologiesjewelry manufacturing

Industries and application areas:

spaceaviationautomobileengine buildinginstrument engineeringmedicine

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The main benefit of cooperation with SEMAT isthe ability to obtain products with unique properties that provide radical competitive advantages, or significantly reduce the cost by using electrophysical processing methods or ultrasonic shot peening.

Partnership with us allows one to achieve significant results:

reduced labor costs,reduced processing time,no tool wear,improved surface quality,reduced production cost,improved product quality, increased product competitiveness.

Roman RyazantsevHead of Sales and Marketing

Department

Our key advantages:

pre-sale test processing and R&D,

own technologies and patents,

simple and convenient control system,

flexible adaptation to customer requirements,

technical and technological support,

after-sales period (2 year warranty + service).

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Partnership with SEMAT gives the opportunity to achieve many production targets

Design and production of high-tech machines:

Services for manufacturing companies:

electrochemical machining (ECM);electrical discharge machining (EDM);ultrasonic shot peening (USP).

ECM - EDM - USP;R&D and engineering.

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Research & Development

Our innovative activities in Skolkovo touch upon research and development in the following areas:

design and manufacture of machines for multi-axis electrochemical machining with rod-shaped electrode tools;design and manufacture of ultrasonic shot peening machines with artificial intelligence in the control system.

As a result of research activity in electrochemical machining an innovative project is being released - creation of an experimental industrial sample "Electrochemical multi-axis modular machine for processing by rod-shaped rotating electrode" with the possibility of starting serial production. Target product is electrochemical multi-axis modular machines which can process all conductive parts with higher quality surface without a special electrode (with a universal type electrode like "milling cutter" or "wire") on CNC program. There is also no need for consumable materials (except aqueous electrolyte solution) and the structure of the part is not changed under processing (heating, peening, etc.). The modular system will allow to meet the needs of a specific customer the fastest way in obtaining a complete "turnkey solution" for an electrochemical machine and technology for specific production requirements at an optimal price.

As part of research in the field of ultrasonic shot peening, some innovative solutions have been worked out in order to improve the design of waveguides, software and hardening technology. We also develop an experimental base for using artificial intelligence algorithms in the control system. The target product of the project is ultrasonic shot peening machines with artificial intelligence in the control system, as well as their mobile versions.

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Patent for invention № 2622075 «Method of electrochemical dimensional machining with a rotating electrode with an eccentricity of the working surface»- Patent holder: SEMAT LLC,- Request № 2016115385,- Priority of the invention: 20th of April, 2016,- Date of state registration in the Government register of inventions of the Russian Federation: 9th of June, 2017,- The exclusive right to an invention expires: 20th of April, 2036.

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Boris ReshetovTechnical Director

Our practical cases of the complex manufacturing challenges

Example № 1 ECM technology application in instrumentation and microelectronics.

Task: a small batch of substrates (500 PCs.) with a ring-shaped groove in the center for hybrid chips.

Problem: when using stamping, an unacceptably large rounding of the edges of the groove is obtained. Insofar as the material is soft, the edge of the groove is raised during machining. During EDM processing the edges become perfect, but an unacceptable defective layer is appeared after that.

Solution: ECM processing was implemented to get the desired shape of the edges and bottom of the groove. There is no defective layer, and the roughness meets the drawing requirements. The equipment is simple and easy to manufacture. The electrode does not wear out during operation.

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Example № 2 Application of the wire EDM machining in instrument engineering.

Task:

Production of a crown gear in the amount of 300 pieces.Workpiece - hardened steel AISI 420. Product dimensions D10 x 3.8 mm.

it is necessary to ensure the accuracy of manufacturing the radius between the teeth - R0. 1 mm,it is necessary to ensure the surface roughness Ra 0.25.

Problem:

Solution:

Gears manfacturing is carried out by means of wire EDM machine SEMAT SkW5030L;

Geometric shape with a radius of R0. 1 mm is made by using a D0.1 mm brass wire;

Roughness Ra 0.25 is obtained in 5 passes due to our own processing program;

Usage of a collet chuck allows one to produce 10 gears at onc. This fact significantly reduces

the cost processing of the total parts lot.

Example № 3 Application of ultrasonic shot peening in aircraft engine building.

Problem:

Solution:

Task:

it is necessary to increase the lifetime of turbine blades for a modern turbojet engine.

to solve the problem one can apply surface deformational hardening, but existing shot blasting and shot peening machines often lead to unacceptable deformation of the leading and trailing edges and roughness penalty from Ra 0.2 to Ra 0.8.

ultrasonic hardening ensures uniform processing and does not lead to unacceptable deformations of the blades (the fatigue strength of the blade becomes 10.58 times stronger), and also the design and manufacture of a unique equipment for fast clamping the parts are involved.

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Fe2+

Fe(OH)2

Andrew SeliverstovLeading Engineer

Electrochemical machining (ECM)

Electrochemical Machining (ECM) is a non–contact processing method.

The mechanism of dissolution (removal of metal) during electrochemical machining is based on the process of electrolysis. Metal removal occurs in accordance with Faraday's law. It means that amount of metal removed is proportional to electric current intensity and process time.

Description

Advantages

ECM process of electrochemical machining

high machining performance (linear metal removal rate in precision processing modes is 0.3 mm/min.)

the absence of the electrode tool wear permits to provide for a high machining accuracy and repeatability and also reduces operating costs for mass product manufacturing

finishing processing is not required

high quality of the processed surface

the absence of the defect layer and burrs on the surface

under machining the formation of thermal stresses and microcracks on the surface of the part are excluded

electrode(cathode)

electrode

allowancedissolution

workpiece(anode)

workpiece

electrolyte

electrolyte

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Sk-ECM-DSk-ECM1000, Sk-ECM4000, Sk-ECM8000

function application areamachine type

micro polishing mattingsharpening

deburringpolishingrounding edges

dimensional machiningsinker ECM

multi-coordinate machining

medical instruments,implants,electrical engineering.

fuel equipment parts,pneumatic / hydraulic systems,mechanical engineering.

tool manufacturing,dies / molds,mechanical engineering,medical instruments,serial parts for aircraftand space technology.

Deburring machine Dimensional electrochemical processing machines

Product lineElectrochemical deburring and polishing electrochemical machine

Description: Features:

Electrochemical machine Sk-ECM-D is designed for deburring and rounding sharp edges in parts made of structional, heat resistant, hardened, magnetic steels and alloys, aluminum and titanium alloys.

The application of the machine is effective in the following cases:

for deburring tools, machine parts and devices that have a complex construction,

for deburrng in hard-to-reach places (internal intersections of surfaces, pockets, etc.),

for operations that do not allow changes in the physical and chemical properties of the surface layer after processing.

Compact layout (3 m ) on a single base;

Modular configuration;

Electrolyte filtration system;

Basic parameters alteration according to the customer's requirements;

Technological support:

design and production of manufacturing tooling,

design and production of electrode tools,

optimization of processing modes.

characteristics of Sk-ECM-D machine

kg

kg

mmmm

mm

nos

step

V

V

ll/min

barbar

kWHz

Alternating current, three phase

weight of the mechanical part of the machineworking table size (length x width)tooling fixture on the working tableprocessing timeavailability of tool storage

maximum dimensions of the workpiecelength-diameter-height (with the fixture)maximum weight of the workpiece with the fixture

mains supply, typevoltage, current frequencypower consumption current rangeaccuracy of maintaining the set voltage voltage range

input pressure rangepneumatic system maximum pressure

electrolytes for useelectrolyte tank capacityelectrolyte maximum flow

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Electrochemical sinker ECM machine –

Description

The machine is designed for dimensional shaping (die-sinking operations) of parts made of conductive materials.

Machined surface formation is achieved by reverse copying the size and shape of the electrode-tool under workpiece anodic dissolution.

Differentiation of access rights, monitoring and work logging;

Expert system that facilitates the selection of new parts processing mode;

Automatic identification of the workpiece, program selection and counting of machined parts.

possibility to install additional CNC ontrolled axes,

possibility to be included in automated production lines.

maximum DC current, Amaximum pulse current, A

maximum processing area, cm

variable parameter (on request)(up to 4 axes on request)

space required for the machineworking table sizenumber of controlled axesZ axis travelZ axis travel accuracyrapid travel speedworking feed rateelectrolyte tank capacity

Vladimir BarakovProjeсt manager

Features:

Additional options:

machines’ parameters

General specification:

mm

l

mm/minmm/min

mm

m

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Ultrasonic shot peening (USP)

Description

Ultrasonic deformational hardening benefits:

Advantages:

Ultrasonic hardening application area:

Yana KanaevaLeading process engineer

Ultrasonic shot peening of complex parts is carried out due to the kinetic energy of moving steel balls using (or not using) fine-dispersion powdered alloying materials.

static strength increase by 13 ... 50%;life stress cycles increase up to 10 times;dimensional changes – 1 ... 2 µm

automatic part identification and appropriate program selection

modern component base

compact size

user-friendly and intuitive interface

possibility of remote monitoring and factory networking

possibility of remote updating of the expert system intelligent database (in order to simplify the selection of machining modes for new parts)

hardened parts automatic counting

work logging

programs database storage and modification

parts of aircraft gas turbine engines,parts of vehicle gearbox, transfer case and chassis,engine parts (connecting rods, bolts,levers, valves),sports weapon parts,stamping equipment, metalwork and assembly tools.

Ultrasonic shot peening machine Sk-UIT350

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Product linemachines’ parameters

typical shot peening ultrasonic shot peening

non-uniform machining of complex

parts

high cost

high power consumption

large space required

repair and maintenance costs

uniform machining of complex

parts

high productivity

low power consumption

compact size

low repair and maintenance costs

max. dimensions of parts for machining, mmmax. weight of parts for machining, kg waveguide dimensions, mm

machine dimensions (LxWxH)machine weight machine productivitydiameter of steel ballsmachining time of 1 part or batch of partsmachine power three-phase electric power supply with zero wire

General specification:mm

mmmin

kWHzV

kgPCs/h

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We offer research and development work by electrophysical methods of metal processing.

You get significant competitive product advantages for many years to come.

R&D

Engineering services

ECM - EDM- USP services

Konstantin IvanovProcess engineer

Development and implementation of turnkey technological solutions based on SEMAT machines for the aerospace industry, machine industry and medicine.

Design and comissioning of manufaturing tooling.

EDM and ECM machining of dies and molds forming surfaces, working surfaces of cutting inserts and impact tools, parts made of stainless steel, heat resistant, titanium, hard and other alloys;

Electrochemical dimensional machining and / or electro-plasma polishing of implants and medical instruments made of stainless steel, titanium, cobalt-chromium, etc.;

Electro-plasma and electrochemical polishing of external and internal surfaces of parts, dissolution of metal burrs in hard-to-reach places, including post processing of parts made with additive methods using metal powders;

EDM wire cutting;

Ultrasonic surface hardening by metall balls.

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a new word in metalworking!

SEMAT facilities

SEMAT being a startup is also:

Wire EDM machine;

Sinker EDM with a movable table;

Universal precised ECM machine for precision dimensional electrochemical machining (die sinking);

Electro-plasma polising mashine;

Ultrasonic shot peening machine;

Electrochemical deburring machine.

A rare businesschain in Russia - involvement from R&D up to serial production;

A professional team consisting of experts in technology, production and sales;

Practical experience and good reputation amoung Customers;

Successful resident of the Skolkovo Innovation Center;

Reliable Russian manufacturer of high-tech machinery for metalworking.

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SEMAT – we focus on complicated challenges!

121205, Moscow,Skolkovo Innovation Center,Bolshoi Bulvar, house 42, building 1

«SEMAT» LLC (tm SEMAT) develops and manufactures electrochemical and electrical discharge machines for metal parts processing, as well as ultrasonic shot peening machines.

micromechanics and microelectronicsdie and molds manufacturingpower engineeringweapons manufacturingadditive technologiesjewelry manufacturing

Our technologies are successfully applied in following industries and speheres:

spaceaviationautomobileengine buildinginstrument engineeringmedicine

Moves Russian machinery forward!