Own development model for Integrated Management of Technological Innovation.
Ultrasonic assisted turning device for the aeronautics sector
Heat-resistant materials such as nickel-based superalloys and titanium alloys are mainly used in the aircraft industry for the manufacture of critical aircraft engine components such as housings and discs. These alloys are among the most difficult materials to machine due to the high capacity to withstand thermo-mechanical loads. The production output of a machining process is closely related to the material removal rate (MMR). With this type of material, due to the high wear and cutting forces generated during machining, the MMR is much lower than that of conventional materials, resulting in long machining times and higher costs.
In this context, Ultrasonic Assisted Machining presents qualities that make it particularly suitable for overcoming the difficulties in machining these materials. This technique consists of applying a high frequency vibration (20-50kHz) to the tool during the machining process. The main advantages of this method of machining are reduction of tool wear and cutting forces, and improvement of surface integrity.
This project serves to develop an industrial ultrasonic assisted turning system to produce aeronautical parts on Danobat"s new lathes, which will improve Danobat"s technological position in the turning sector for aeronautical applications.
Analysis of ultrasonic turning processes: To study the behaviour of ultrasonic turning on materials that are difficult to machine, such as nickel-based heat-resistant alloys and titanium alloys, and the advantages it offers compared to conventional working conditions.
Development of an ultrasonic drive: Design, manufacture and setting of the device capable of being industrialised and which can provide the tool with ultrasonic vibration.
Implementation on a Danobat lathe with an ultrasonic assisted turning system: Installation of the device on industrial lathes to reduce cycle times, cost and energy used during the manufacture of aircraft engine components.
Optimisation of machining by means of ultrasonic assisted turning technology: Increase the material removal rate to achieve shorter cycle times without sacrificing the end quality in the machining of parts of materials used for aeronautical materials such as Inconel 718 or Titanium grade 5 (Ti6Al4V).
Robust equipment for ultrasonic assisted turning that can be sold by DANOBAT as an extra option on its lathes, specifically those for machining engine components for the aeronautical sector. Process windows have been identified in which ultrasonic assisted turning allows for the reduction of cutting forces and tool wear during the machining of heat-resistant alloys. Using the expertise in ultrasonic assisted turning to develop a software tool for high-performance machining of parts made of Inconel 718 or Ti6Al4V.
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