Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: FoF.NMP.2012-5 | Award Amount: 5.01M | Year: 2012
Today, Europes leading position in manufacturing of formed, high-precision 3D metal parts is being threatened by developed non-EU countries that catch up quickly on product quality at low cost. If no further action is taken, loss of jobs and GDP are at risk. To face global competition, a breakthrough is needed in tackling the following four challenges: - Continuous product trend for higher quality, smaller features, at simultaneous demand for lower cost price; - Reduced number of finishing operations and consumption of raw materials and energy; - Reduction of machine downtime; - On-line 100% quality control of 3D complex shapes. HiPr will realise this essential breakthrough. The primary goal of HiPr is to develop and integrate all necessary base technologies which create the basis to control and monitor the condition of micro-tooling for complex high-precision 3D parts. This will be achieved by developing and integrating: in-depth process and material knowledge, in-line measurements, real-time predictive maintenance. Proof will be given on pilot production lines in industrial settings. HiPr will do this with a consortium of partners best-in-class in these fields. The methodology that will be used to come to efficient realisation is the following: Define and describe the process, measure tool performance, model based prediction of tool performance. This methodology will result in reduction of: - cost by >20%; - material and energy consumption by >30%; - development cost reduction >30%. The knowledge-based HiPr results are also applicable in different sectors, leading to low defects, despite customisation trends. HiPr will therefore help in assuring a competitive and sustainable European manufacturing industry.
Agency: European Commission | Branch: FP7 | Program: BSG-SME | Phase: SME-1 | Award Amount: 1.28M | Year: 2011
European SMEs from the manufacturing sector are facing increasing competition, since manufacturing is migrating to low-cost countries even for manufacturing of high value parts in aeronautical or the mold making industry. To remain competitive SMEs must conceive radical new production solutions. Mostly new innovative products come along with the introduction of advanced materials like super alloys or super hard steels, which are extremely hard to machine. However, successful introduction in innovative products requires economic manufacturing processes in a short period of time. In this challenging field most SMEs apply high-performance multi-axis milling. This technology offers maximum flexibility in terms of part geometry and material, but it also requires comprehensive process knowledge. Thus, the main objective of this proposal is to create a novel and holistic, knowledge-based development platform that rapidly provides optimum process design for advanced milling tasks covering tailored coated milling tools including adapted parameter sets and strategies. Process layout must ensure maximum tool life by minimum use of lubricant. The platform will enable the SMEs to achieve a delivery time reduction of highly efficient manufactured components by at least 25% and will consequently enable potential customers to reduce time-to-market and costs for their high quality products made of hard-to-machine materials. This will finally and sustainable strengthen the position and competitiveness of European SMEs in growing markets. Participating SMEs will also contribute to reduce energy consumption by the efficient use of material resources in manufacturing. In addition they will directly contribute to increase energy efficiency at the OEMs mass production (innovative dies and molds) as well as at the OEMs products (lighter jet engines with lower CO2 emission). Both are examples which lead to a significant improvement of environmental and health conditions in Europe.
Agency: European Commission | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2011-1-SAGE-04-013 | Award Amount: 455.00K | Year: 2011
The strong need for higher efficiency, reduced CO2, NOX emissions, weight and noise reduction in aircraft engines leads to a demand of innovative materials with optimized mechanical and physical properties. The special design of new generation geared turbofan aircraft engines with their faster rotating LPT leads to higher temperatures in the turbine, casing and engine mount and thus requires parts with increased high temperature properties. High temperature strength means in most cases bad forgeability and weldability as well as combined with high toughness challenging machinability. Thus, beside of new designs the production processes have to be altered to get high quality parts. The overall goal of this project is an improved understanding of thermomechanical processing and its effect on residual stresses and distortion as well as microstructure and mechanical properties of forgings used for improved temperature exhaust cases. The proposed project consortium has significant experience with regard to nickel base superalloys with higher temperature capability than Inconel718 like Udimet720, Waspaloy, Allvac718Plus, RENE65 and Haynes282. Together with the know-how on residual stress simulation and measurement established in several projects since 2001 a successful realization of this project is possible. Beside project management according IPMA standards six further work packages have been defined. One for radial forging and one for closed die forging will be used to optimise thermomechanical processes based on simulation and to produce demonstrator parts. Open die forgings are used for residual stress and microstructure investigations. Material data for finite element simulation and residual stress modelling will be generated in on work package and verified together with the customer in an other. Residual stress modelling will be verified by neutron diffraction measurements and other methods in the final work package.
Agency: European Commission | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2011-1-SAGE-04-009 | Award Amount: 365.00K | Year: 2011
The objective of this project is the implementation of an integrated simulation chain including pre material characteristics, thermo-mechanical processing (forging and heat treatment) and assessment of microstructure and functional properties for aerospace turbine components. The integration of different computational results within an interdisciplinary and intercompany design-chain is a challenging task. A fully integrated simulation chain along the supply chain will give unique benefit for product development with respect to time, cost, and quality. This allows an optimization of the forgings in respect of weight, efficiency and CO2 reduction. Bhler Schmiedetechnik GmbH & Co KG (BSTG) has developed a model for determining the microstructure (e.g. local grain size distribution in a component) from forging and heat treatment simulations. This model is in daily use for thermo-mechanical process design and optimization of turbine disks. In past, recent and future R&D projects, Bhler Schmiedetechnik has developed models for determining the local functional properties depending on the microstructure. In a further step, aiming to the topic of this proposal, the simulation chain is to be integrated into an industrialized useful format, target-aimed to customer needs. Suitable strategies and methods for integration of the pre-material characteristics have to be assessed. The quality of the existing models has to be evaluated together with the customer. Comprehensive statistic investigations work is necessary in order to make the usage of the simulated data possible at the customer. Detailed investigations have to be executed to improve and/or generate functional properties models like yield stress, low cycle fatigue and creep models. Interfaces have to be defined and generated. A validation work has to be examined with forged LPT (low pressure turbine) demonstrator disks which show the effectiveness and model capabilities.
Agency: European Commission | Branch: H2020 | Program: CS2-RIA | Phase: JTI-CS2-2015-CFP02-ENG-02-03 | Award Amount: 450.00K | Year: 2016
In order to overcome current shortcomings of the state-of-the-art simulation chain, this project will make improvements on microstructural modelling (integration of non-uniform microstructures), billet modelling (evaluation of billet inhomogeneity introduced during feedstock processing) and modelling of materials properties (yield strength variations in circumferential direction, influence of non-uniform grain structures) available to the customer. On the one hand, this means a further development of already demonstrated capabilities of Bhler Schmiedetechnik GmbH & Co KG (BSTG) to simulate microstructural and mechanical properties for increasing prediction fidelity. On the other hand, this is of special importance for efficiency of future engines (i.e., lower fuel consumption, reduction of CO2 emission, etc.), as a fully integrated simulation chain allows for an optimization of forged engine disks in respect of weight and safety. Yield strength variations in circumferential direction were observed in an earlier research project. It was assumed, that this behavior is caused by variations in the billet and certain process conditions during the last forging operation. Aiming to the topic of this proposal, these additional impacts should be analyzed (for metallurgical understanding) and included in an existing mechanical properties simulation tool (for quantitative prediction). The influence of inhomogeneous breakdown and converting of the billet will be elaborated together with the billet supplier Bhler Edelstahl GmbH & Co KG (BEG). This close collaboration is essential to enable a fully integrated simulation chain. After establishing a grain class model to predict duplex grain structures, the effect of duplex grain size on yield strength and fatigue properties will be studied. Finally, a validation has to be done on forged turbine disks to show the effectiveness and capabilities of the further developed mechanical properties simulation tool.
Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: NMP.2010.2.5-1 | Award Amount: 3.68M | Year: 2011
Engineering ceramics possess superior mechanical and physical properties. The exceptional wear, corrosion and contact fatigue resistance of silicon nitride and SiAlON ceramics makes them attractive materials for high temperature metalforming tools and rolling elements for bearings. Despite the efforts devoted to study this class of materials, there still exists a gap between their microstructural properties and their potential application limits. Developing multiscale predictive models that deliver information on materials degradation mechanisms, based on realistic working conditions, will enable the systematic tailoring of ceramic materials for new applications, supported by validated evaluation techniques including tribology, damage analysis, and lifetime predictions. The optimisation of the microstructure is clearly application-dependent and should rely on co-related material development efforts and multiscale simulations. The bridging between the microstructural properties and macroscale behaviour should merge the knowledge acquired from the atomistic, microscale, mesoscale and macroscale levels. Nonetheless, the chain of information would not be complete without including means of validation that rely on experimental techniques and functionality tests in real applications.
Bohler Edelstahl Gmbh | Date: 2014-12-02
The disclosure relates to a production of a semi-finished product for a manufacturing of objects, particularly tools, from a precipitation-hardenable alloy having a composition in wt. % of Co=15.0 to 30.0, Mo up to 20.0, W up to 25.0, Fe and manufacturing-specific impurities as a remainder. To achieve an economical, highly precise production of objects or tools of the above alloy with reduced effort, it is provided to prevent a formation of ordered structures of the Fe atoms and Co atoms in the matrix of the type (Fe+(29Co))+approximately 1 wt. % Mo of the semi-finished product by a thermal special treatment, to thus improve a workability of the material.
Bohler Edelstahl Gmbh | Date: 2015-06-25
A hot-forming steel alloy comprising, in addition to iron and impurity elements, carbon, silicon, manganese, chromium, molybdenum, vanadium and nitrogen within the concentration ranges set forth in the claims. This abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.
Bohler Edelstahl Gmbh | Date: 2011-10-17
The invention relates to a method for the production of tools for a chip-removing machining of metallic materials and to a tool with improved wear resistance and/or high toughness. The invention further provides an alloyed steel with a chemical composition comprising carbon, silicon, manganese, chromium, molybdenum, tungsten, vanadium, and cobalt as well as aluminum, nitrogen, and iron. The alloyed steel may be used to make tools to a hardness of greater than 66 HRC and increased chip-removing machining performance.
Bohler Edelstahl Gmbh | Date: 2011-04-05
Gun barrel for firearms made from a deformed material and method for producing the gun barrel material. The material has a chemical composition in % by weight of: and impurities due to smelting. The material has a hardness of at least 46 to 48 HRC.