Project Consortium

Project Coordinator

© IWF, TU Berlin

The Institute for Machine Tools and Factory Management (IWF), part of the Technical University Berlin (TU Berlin) is a world-leading institute in the fields of machining technology, machine tools, control and assembly techniques, industrial information technology and quality assurance. The IWF focuses on the technological and design development of processing devices, as well as the planning and optimisation of their application in the manufacturing process. The Department for Machining Technology and the Department for Machine Tools, within which the ConTemp project will run, specialises in the development, analysis and optimisation of processing technologies such as high-speed cutting of high strength and high temperature alloys. Current projects include the development of high speed machining of nickel based super alloys, milling of dies and machining of non-ferrous alloys. The departments have undertaken extensive theoretical and experimental research of the cutting process, with particular emphasis on the dynamic and thermal behaviour of the machine tools, as well as the technological analysis of tool temperatures, tool wear and surface properties of the workpiece. Additional expertise on advanced automation and control systems can be provided by the process monitoring and control research group in the IWF. The group is lead by Eckhard Hohwieler and has a wide experience in the build-up and configuration of control systems. The IWF will provide a wide range of machining equipment as well as a number of model wear tests for the ConTemp project. Aside from the project management tasks of the project co-ordinator, the IWF will be involved in the process analysis, manufacturing of the cooling tool system and in the testing and optimisation of the tool. The institute will also promote the technology through dissemination and exploitation of project results.

www.iwf.tu-berlin.de

Project Partner

© Brunel University

Brunel University is a leading research university based in west London, UK. It has 1,000 academic staff and 15,000 students, of which 3,000 are engaged in postgraduate research study. The Advanced Manufacturing & Enterprise Engineering (AMEE) Department at Brunel University is one of the first integrated innovative engineering disciplines in the United Kingdom. The department, under the leadership of Professor Cheng, has been involved in a number of research projects relevant to the subject matter of ConTemp such as:

Development of a 5-axis micro milling machine and associated nano/micro machining technology (MASMICRO, EU-FP6-IP NMP2-CT-2-4-500095).

Design of 5-axis UMAC-based CNC control system in collaboration with Delta Tau UK Ltd.

Development of smart/intelligent toolings applied to a CNC machining system (SEEM), funded by UK Technology Strategy Board (BD266E).

EREE-based low carbon manufacturing (Energy and resource efficiency and effectiveness): fundamental, methodology and applications, funded by the industry.

The University has created a state-of-the-art micro manufacturing facility, and has undertaken extensive research in the areas of cutting simulation, self-learning control systems, process monitoring and optimisation and precision machine tool design (diamond turning, micro milling and micro grinding). Within ConTemp, Brunel University will be primarily involved in the modelling and design of the tool system and implementation of the self-learning control system. Professor Cheng and Dr. Bateman will be the leading researchers working on the ConTemp project at Brunel University. Prof. Cheng has, throughout his career, published extensively in the fields of micro manufacturing, design of precision machines and precision manufacturing. The Advanced Manufacturing and Enterprise Engineering (AMEE) Department at Brunel University is one of the leading research departments in Europe, in advanced manufacturing technology in particular. Additionally, Professor Cheng is the European editor of the International Journal of Advanced Manufacturing Technology and an editorial board member of the International Journal of Machine Tools and Manufacturing. It is foreseen that a special issue of one or both of these journals to be published, demonstrating the research results arising from the ConTemp project. Dr. Bateman is an expert in rapid manufacturing and adaptive manufacturing systems and has published extensively on these topics.

www.brunel.ac.uk


© FIAT

Centro Ricerche FIAT (CRF), with headquarters in Turin, was established in 1976 to carry out the research and development of the FIAT group. The Materials and Process Technologies Business Unit, which will be partaking in the ConTemp project, deals with the R&D of innovative processing technologies, in particular cutting tools and cutting strategies, for the manufacturing activities of the FIAT group. CRF will contribute to the ConTemp project as an end-user, and will be involved in the process analysis, development of manufacturing processes and testing of the system as well as in the industrial assessment phase of the project. The team of machining experts at CRF have a dedicated machining laboratory at their disposal to carry out the experimental cutting trials and system validation. CRF has extensive experience in partaking in EU Projects, and is currently involved in a number of projects, the most relevant being:

Innovatial: innovative coatings for automotive and aerospace applications.

Next: next generation machine tools

Affix: flexible and intelligent fixturing for automotive and aeronautical components

Promach: improvement of machinability of powertrain materials

Int-Manus: virtual manufacturing

I-Proms: noE on manufacturing

Dr. Anja Herrmann Praturlon is head of the High Efficient Machining Group at CRF and will be co-ordinating the ConTemp activities at the company. She has extensive experience in the optimisation of production processes, application of innovative coatings on production tools and flexible manufacturing process chain design and has in recent years been involved in strategy development for cost, energy and resource reductions within CRF. Dr. Anja Herrmann Praturlon will also be undertaking the research work within ConTemp at CRF. She is a mechanical engineer with experience in the simulation of cutting processes, optimisation of cutting tool substrates and coatings, manufacturing systems design and the development of new cutting processes for difficult to machine materials.Ms. Hermann Praturlon has been involved in a number of projects within the FP5, FP6 and FP7 frameworks, such as Ecosystms, Sammi, Amadeus, Alumopla, Autofett, Alticut, Ulmat, Ultraflex and Mantes.

www.crf.it


© DIAD

DIAD srl. is a high tech SME involved, since 1987, in several industrial businesses related to the collection, storage, treatment and recovery/recycling of dangerous and not dangerous materials and the development of new cleaning technologies. DIAD is a leading company in its sector, with more than 3500 customers and strong partnerships all over the world. The company finds its success factor in the constant transformation of the knowledge produced by applied research into products, technologies and services for different industrial sectors, such as the aerospace manufacturing and automotive industries. DIAD invests a large portion of its annual revenue in applied research, through its dynamic R&D team, which serves all the industrial sectors covered by the company. New technologies and processes are designed and benchmarked through integrated approaches based on environmental compatibility, life cycle analysis and cost effectiveness. DIAD is actively involved in several European financed projects, where new advanced technologies are

integrated for a new generation of clean, efficient and high quality manufacturing processes and new product embedded technologies (FP6 AFFIX, RAPOLAC, HYDROMEL IPs and FP7 INTEG-MICRO and ADACOM). Dr. Sergio Durante graduated in mechanical engineering from the Politecnico of Torino and was responsible for advanced research projects on manufacturing technologies in a large automotive research centre for 13 years, where he was leader of the machining department and responsible for the technology transfer to FIAT Group companies such as Ferrari, Maserati Comau, AlfaRomeo, Lancia, CASE New Holland. He has acted as the coordinator in several European financed projects, where the most important European Universities, Industries and Research Institutes were involved. Today he is the executive vice president of DIAD, where he is also responsible for technology transfer in the aeronautic and aerospace sectors. Author of more than 60 publications, he is a member of the scientific committees of several technical international reviews.

www.diadsrl.com


© rho-BeSt Coating GmbH

KOMET RHOBEST GmbH is an SME which was founded in 1996 in Innsbruck, Austria. The core business area of Rho-BeSt is the production of Chemical Vapour Deposition (CVD) diamond coatings. Since 2000 the company produces coatings particularly for the wear protection of tools for the machining of graphite, aluminium and aluminium alloys as well as fibre reinforced composites on an industrial scale. Rho-BeSt is actively undertaking research in interdisciplinary fields such as:

  • wear and friction of NCD-coatings:

    development of NCD-layers for machining of new materials and composites development of NCD strong adhesion (including matching interlayers) on different substrates, steel, low temperature material (CMOS)
  • bio-sensors
  • implants/substrates for tissue engineering
  • MEMS/NEMS

The high level of international collaboration has been reflected in the success of Rho-BeSt nano-diamond (NCD) und ultra-nano-crystalline diamond (UNCD) material.

Within ConTemp, Rho-BeSt will be involved in the design and manufacture of the selfcooling tool, where diamond coating expertise will be of upmost value to the project. The company will also be involved in the integration of the tool within the self-learning system and in the exploitation of the technology through its wide customer base.

Dr. Herwig Drexel will co-ordinate the work within ConTemp at Rho-BeSt. After attending the Federal Secondary College of Mechanical Engineering (HTL) in Innsbruck, he graduated from the University of Innsbruck in Physics in 2002. Dr. Drexel will be responsible for the experimental design of the cooling device and the diamond coatings. He will decide on experimental parameters and ensure that coatings of the highest quality are delivered. He will lead the internal work group and will instruct the coating personnel on the individual requirements.

www.rhobest.com



© C.F.K.

C.F.K. CNC-Fertigungstechnik Kriftel GmbH is an SME specialising in the production of complex parts using a generative manufacturing technology. The founders of inno-shape developed the Direct Laserforming Process at the Fraunhofer Institute for Laser Technology (ILT) in Aachen prior to founding inno-shape in 2004. The company specialises in the production of laserformed parts from aluminium, nickel, titanium and tool steel. With the lasersmelting process, components with complex geometries can be manufactured layer-by-layer on the basis of 3D-CAD data, meaning an increased productivity can be achieved.

The company has previously been involved in a number of relevant projects. These include direct process developments for customers as well as publicly founded projects for special materials and applications. In addition inno-shape provided special designs and suuport for laser melting equipment.

Inno-shape will be involved in the design and production of the micro-cooling system within the ConTemp project. The company's know-how in the production of micro cooling devices will be valuable for the project, and the laser smelting production technology offers the opportunity to produce the tool system in a cost and time efficient manner.

Dr. Christoph Over will undertake the research work at inno-shape. He received his doctorate from the Fraunhofer ILT in Aachen in 2003 and is a founding partner of inno-shape. Throughout his career, he has gained 5 years of research experience as an employee of the ILT in the fields of process and equipment development for the laser melting process and general laser materials processing technology.

www.cfk-online.de


© UPM

UPM ltd. (UPM) is an SME, founded in 2006, which specialises in the design and development of machinery that is required in ultra precision motion. In collaboration with Brunel University and funded through the FP6 framework, UPM developed a 5 axis micro milling machine having an extremely high precision specification. UPM has also developed micro recessed air bearings that enable a substantial improvement in stiffness compared to conventional air bearing designs. The company has gained extensive experience in the design of CNC controls and self-learning systems, and will thus be involved in the design, development and integration of the self-learning system within ConTemp.

Dr. Frank Wardle will undertake the research within the ConTemp project at UPM. Following graduation from the University of London in 1974 he has gained experience in the field of precision engineering, undertaking basic research and development projects on all types of precision bearing. He has also developed novel grinding, turning and milling machine tools and electrochemical machining processes for modifying bearing surfaces. Dr. Wardle has more than thirty years’ experience in an industrial research environment and has authored more than 30 technical papers and 12 patents, and gained 2 best paper awards from the UK’s Institute of Mechanical Engineers.

www.upm.org.uk


© WCarb

Wolframcarb s.p.a.a. (WCarb) is a hard metal parts manufacturer (inserts, cutting tools, mechanical parts, die) which supplies hard metal mechanical parts to most of the automotive European companies and a good variety of other industrial sectors, mainly within the EU.

The strategy of the company has always been to equip the production with sophisticated machinery with characteristics allowing product flexibility enabling to obtain quality at relatively low costs This emphasis in quality control has been a key factor in the company’s success within sectors such as the automotive where end-users demand a well-established confidence level for the tools used in high productivity chains. Difficult to machine materials represents great potential for company growth in the future which can be achieved by using new coating processes combined with customised tools.

Since its foundation, fifty years ago, Wolframcarb has enjoyed steady growth and has reached a leading position in more than 70 countries world-wide. This achievement is the result of research, permanent experimentation, sophisticated production processes, advanced technology, highly specialised staff and quality products warranted through rigorous final testing.

Nowadays, the company mainly excels in the production of tungsten carbide tools to use on machine tools for generally mechanical workings. Besides the use on machine tools, tungsten carbides find good application in the following fields: Difficult to cut materials machining, Wood working, Stone, granite, Application in mines, Application in steel mills, Application in military industry, Application in mechanical industry.

Wolframcarb has a large number and choice of sintering facilities, so they can produce also customized tools and inserts using different carbide, PM HSS and ceramic substrates.

www.wolframcarb.com


© Dr. Ebert Technologieberatung GmbH

Dr. Ebert Technologieberatung GmbH, Germany

Dr. Thomas Ebert is an expert in Laser Technology and the design and manufacturing of micro-cooling systems. The role of Dr. Ebert Technologieberatung in the ConTemp project consists of the design and development of the high performance micro cooling devices for the cutting tools.