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FEANOR UFP Cutting Tools & Metrology 芬诺 UFP 刀具及测量仪研究发展有限公司

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Presentation of 4 activities n Special Cutting Tools 非标刀具 刀具 o Measuring Systems 测量仪器 + laser 激光干涉仪 p Software for Quality 质量控制软件 + calibration q Research Projects coordination 欧盟框架研究计划

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by Luca G. Bochese 卢卡, CEO Feanor

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n Feanor - Special Cutting Tools „

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FEANOR designs special cutting tools in HSS and solid carbide 设计非标刀具在高速钢和硬质合 金 Manufacturing is made by partner company UFP in Italy (presentation + movie) 制造业是由合作伙 伴UFP公司在意大利(介绍+电影)- started 1993


n Feanor - Special Cutting Tools „ „

Virtually all types of special cutting tools: drills, cutters, reamers, counter-borers, threading mills, taps 几乎所有类型的非标刀具:钻,铣刀,丝锥,铰刀,螺 纹铣刀

Automotive, Aerospace, Defense, increase in Power Generation Systems (turbine shafts and blades) in the last 5 years 汽车,航空航天,国 防,增加发电系统( 涡轮轴和叶片)


n Feanor Special Cutting Tools „

Main Customers: Siemens, Mitsubishi, Alsthom, General Electric, GE Power Systems 主要客户有: 西门子,三菱, Alsthom , General Electric, GE Power Systems

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Countries: Italy, Germany, France, Hungary, USA, Russia, China 国家:意大利,德国,法国,匈牙利 ,美国,俄罗斯,中国


1. UFP 非标刀具制造公司 Virtually all types of special cutting tools: drills, cutters, reamers, counter-borers, threading mills, taps 几乎所有类型的特殊刀 具:钻,铣刀, 丝 锥,铰刀,螺纹铣刀


1. UFP 非标刀具制造公司 „ „ „ „ „ „ „

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Active since 1987 40 people turnover 5 million € 2 plants in Italy 积极自1987年以来 40人 成交量50.000.000 元 工厂在意大利


1. UFP 非标刀具制造公司 „

Automotive, Aerospace, Defense, increase in Power Generation Systems (turbine shafts and blades) in the last 5 years

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汽车,航空航天,国 防,增加发电系统( 涡轮轴和叶片) , 在过去五年


新的专利技术 „

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Solid carbide, three helix cutting edges, internal cooling 固体碳化物,三螺旋锋利,内部冷却 This is just an example of improvement in manufacturing efficiency. UFP is working in many different areas: automotive, defense, power generation, ... 这只是一个例子,改善生产效率。 UFP 工作在很多不同的领域:汽车,国防,发电,…


New patented design for gas turbine rotors 新的专利设计的燃气涡轮转子 „

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Use of 2 solid carbide tools instead of 4 tools 使用2硬质 合金刀具,而不是4刀具 Save of presetting time (compared to insert tools), from 1400 hours to 800 hours for complete shaft manufacturing 节省的预设时 间(相比插入刀具) ,从 1400时至900小时,完成骨干 制造业 Cost reduction from 50.000 $ to 19.000 $ per shaft 降低成 本,从500.000元至190.000 元


Aircraft turbine rotors manufacturing „

Same technology, different profiles and sizes, used in military and civil aircraft engines同样 的技术,不同功能与尺寸 ,应用在军用和民用飞机 发动机上


Turbine manufacturing: blade foot „

Similar base profile as rotors, different tools for blades and blade bases 类似的基地, 作为转子,各 种工具,为叶 片与叶片基地


Blade foot: new UFP technology „

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one tool for both roughing and finishing, alternate teeth. HSS body, HM brazed inserts 一个单一的刀具都粗加工 和精加工,候补牙齿。届 时,高速钢体,硬钎焊金 属刀片 Increase efficiency 30% 提高效率是30 %


Rotors: traditional technology „

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Traditional technology uses indexable tools (inserts) or 4 tools, with one taper tool before profile tool传统的技术 是使用刀片或4刀具,其中一 个圆锥刀具之前剖面刀具 Inserts: Long time required for tool presetting (main disadvantage) 刀片:长所需 的时间刀具预(主要缺点)


Blades: traditional technology for surface 叶片: 叶片:传统制造技术的表面 „

Traditional technology for blade surfaces is insert milling cutter for roughing and finishing

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传统工艺为叶片表 面是插入铣刀用于 粗加工和整理


Blades: UFP technology for surface 叶片: 叶片:传统制造技术的表面 „

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UFP technology for blade surfaces is solid carbide milling cutter for roughing and finishing with 4, 6 or more cutting edges UFP工艺为叶片表面 是固体硬质合金铣刀 粗加工和精加工4, 6 或更锋利


Rotors: new UFP technology „

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Roughing without taper groove (from scratch) and finishing. Without or with cooling (better) 粗而不锥槽(从零开始) ,并整理。没有或冷却(较 好)

HSS for old machines

HM for new machines

高速钢旧机器

硬质合金新机


Requirements for new UFP technology 要求要使用新技术 „

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Machine stiffness, good basement 机床刚度 好,地下室 Highly efficient cooling system 高效冷却系 统 (For blades) CNC machines with 3, 4, 5 and 6 axis (20 spindles) (涡轮叶片) ,数控机 床与3日, 4日, 5日和6轴( 20锭)


Rotors: UFP HM 切削参数 „

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Roughing: HM+cooling Ø60, 460 rpm, feed 64 mm/min Finishing: HM+cooling dia 60, 800 rpm, feed 140 mm/min 粗:硬金属+冷却,直径60毫米,460 rpm,64毫米/ 分钟 整理:硬金属+冷却,直径60毫米,800 rpm,140 毫米/分钟


Rotors: traditional technology


Rotors: UFP HM technology


Rotors: UFP HM technology


Rotors: UFP HM technology


o Feanor Measuring Systems „

Metrology activity started in 1992 with cooperation with Helios (now belonging to Mahr). Focus on shaft measurement. 计量活动始于1992年,合作与

太阳神(现属于Mahr) .重点骨干测量。 „

Contacts with all metrology main companies (Zeiss, DEA, SIP, Trimos, Tesa,) because of QMSOFT calibration software and LP30 laser calibration system 同一切计量主要公司(蔡司,

DEA,SIP,Trimos ,Tesa )这是因为QMSOFT校 准软件和LP30激光校准系统


o Feanor Measuring Systems „ „

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High precision length MS 高精度长度测量系统 Measurement systems for diameters 测量系统 为直径 Gear measuring systems 齿轮测量系统 Measurement systems for the workshop and for the calibration room 测量系统,为车间和为校准 室 Looking for cooperation with Chinese manufacturers of measuring systems 寻求合作 ,与中国制造商的测量系统


o Feanor Measuring Systems


o LP30 Compact Laser Measurem ent Dis tance Velocity Angular Straightnes s measurement (with angular optics) Flatness** Straightnes s measurement (with W ollastone prism) Squareness Angular measurements

R ange 0 – 30 m 0 – 0,3 m/s (0,1 m/s) * 0 – 3600 arcsec 0 – 12 m

Resolution 0,01 µ m (0,001 µ m)* 0.25 µ m/s 0,04 arcsec 0,02 µ m (for 100 mm base)

Accuracy 1,5 µ m/m 0,1 % ± 0,2 % ±1%

0 – 12 m (± 3 mm flatness measurement range) 0 –3 m

0,02 µ m (for 100 mm base)

± 0,5 %

0.01 µ m

±1%

± 1000 arcsec ±5°

0,03 arcsec 0,04 arcsec

± 1 % ± (1,5 arcsec) ± 0,2 %

Calibration of CMM and inspection of geometry and axis displacement on machine tools校准测 量仪器和检查几何和轴 线位移机床


o LP 30 Compact „

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Displacement measurements with the use of a laser interferometer allow obtaining the accuracy of an displacement measurements of 0.4 ppm in air and 20 nm in vacuum 位移测量激光干涉仪有一个精度的位移测量的0.4 ppm的空气和 20 nm的真空 The output beam of a Zeeman laser consists of two circularly polarized beams, one with left polarization and one with right polarization

输出光束一塞曼激光器连续两个圆极化横梁,其中左 极化和一名与权利两极分化


o Basic Michelson interferometer Reference reflector

Z1

f1

Z

f1

Moving reflector

f1 f1

Z2

Coherent light source

f1 m f D

f D = 2 f1 vc Detector

x

fD

f D - frequency resulting from the Doppler effect


o LP 30 Compact Reference reflector

Two perpendicular linear polarizations

位/4 Zeeman laser

f1

f1

f1 f 2

f2

Polarizing splitter Two circular polarizations

f2 f1 m f D

f2 f1

f1 m f D

x

Polarizers f 2 - ( f1 m f D )

f 2 - f1

Moving reflector

f2

f2

Nonpolarizing splitter

fD

f D - frequency resulting from the Doppler effect f D = 2 f1

v

c vertical polarization Photodetectors Reference path

Counter

Counter

Substractor

Measurement path

horizontal polarization


o Heterodyne method Reference reflector

Two perpendicular linear polarizations

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In the heterodyne method, shown on figure 2.3, two laser frequencies are used. Therefore a twofrequency laser is needed, e.g. a Zeeman laser. A twomode laser is not suitable for the heterodyne method interferometer, because the difference between f1 and f2 is usually too high for an electronic counter

λ/4 Zeeman laser

f1 f 2

f1

f1 f 2

Polarizing splitter Two circular polarizations

f2 f1

f2 f1 m f D

f1 m f D

x

Polarizers f 2 - f1

Moving reflector

f2

f2

Nonpolarizing splitter

f 2 - ( f1 m f D )

fD

f D - frequency resulting from the Doppler effect fD = 2 f1

v

c vertical polarization Photodetectors Reference path

Counter

Counter

Substractor

Measurement path

horizontal polarization


o Disadvantage of Michelson interferometer „

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The main disadvantage of Michelson interferometer results from the fact that the detector cannot determine, whether fD is negative or positive thus, from the measurements the displacement of the moving reflector without the sign is obtained. Currently there are widely used two methods that allow getting also the direction of the movement. Depending on the number of light frequencies (wavelengths) used in the interferometer, the first is called homodyne (one frequency) and the second heterodyne (two frequencies) method


o Errors „ „ „ „ „

Errors caused by the environment Dead path error Cosine error Abbe error A laser stability error


o Errors without environmental compensation Laser

Environment

Cosine

Dead path

3

4

Electronics

Unlinearities

Thermal drift

1

0

1

2

5

6

Positioning error [um/m]

7

8

9

10


o Errors with environmental compensation Laser

Environment

Cosine

Dead path

Electronics

Unlinearities

Thermal drift

1

0

0,05

0,1

0,15 Positioning error [um/m]

0,2

0,25

0,3


p Feanor - Software for Quality „ „ „ „ „ „ „ „

QMSOFT - calibration GAGEPACK gage management GUM WORKBENCH - uncertainty SQCPACK - process control DOEPACK - DOE FMEA - failure analysis PORTSPY - serial port MEASURESPY - CMM


p Where to download demos „

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On www.feanor.com you can download all demo of software and manual and technical description of the laser interferometers 对www.feanor.com你还可以下载演示版软件和 手册和技术说明的激光干涉仪


Examples of standards for calibration of thread gauges (abstract) included in QMSOFT


p QMSOFT „

More than 500 calibration laboratories,using QMSOFT, including e-calibration service


p QMSOFT „

Specific measurement software modules, according to gauge type (length, pressure, force,…) 具体测量软件模块,根据文书的类 型(长度,压力,力, …


p QMSOFT „

Tolerance calculation according to standards, for many types of measuring instruments 计算 公差按标准,对许多类型的测量仪器


p QMSOFT „

Measurement of the gauge according to calibration procedure 测量仪器按标定程序


p QMSOFT calibration certificate „

Creation of the calibration certificate 开设的校 准证书


p Feanor Software for Quality „

GAGEpack a powerful and easy tool for MSA – Measurement System Analysis or R&R – Repeatibility and Reproducibility according to AIAG Standards

一个强大和容易的工具,测量系统的分析 (software for industrial and practical use, does not include standards as QMSOFT) ( 软件产业和实际用途, ) 软件产业和实际用途, 不包括标准 QMSOFT)


p GAGEpack EZ „

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GAGEpack EZ is a powerful gage calibration software for application in industry, to manage a complete history of measurement devices, instruments, and gages. 是一个功能强大的计校准软 件,为在工业上的应用,以管理一个完整的历史上的 测量设备和仪器。 It generates calibration schedules and alerts about failed and past due calibrations 它产生的校准时间表 和警报约失败而过去由于校准 It tracks location and status, maintains repair records, and provides an audit trail for traceability 它的轨道位 置和地位,保持维修记录,并提供了审计线索溯源


p GAGEpack EZ „

GAGEpack EZ follows AIAG's recommendations to help to conform to ISO/TS 16949-2002, and other critical calibration standards, increasing the accuracy and efficiency of gage management.


p Tracking of calibration costs


p Status of gages (usable, overdue for calibration, repair, scrap, transferred, usable with limitations, ‌)


p GAGEpack EZ „

GAGEpack EZ allows you to create reports, print calibration labels, and customize any existing report. Reports provided with GAGEpack include:

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Calibration planning report 校准规划报告 Calibration history 校准历史 Gage R&R summary 仪器重复性和可重复性摘要 Gages by location, job number, etc. 仪器由所在地,就业人数等 Gages usage 仪器使用 Certificate of calibration 校准证书 Gages due and overdue for calibration 证书到期,并逾期未校准 Labels 标签

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Audit trail 审计线索 Pending alarms 待警钟 Gages due for R&R analysis 票据到期的重复性和再现性分析 Inventory 库存 Calibration and R&R results 校准和可重复性和可重复性的结果 And 90 more reports! 和90多报道!


p MSA using GAGEpack „

Setting up a MSA measurement study requires a reminder that the measurement system includes equipment, technique, environment, and people involved. Each of these factors (Equipment, Appraisers, Samples, Procedures) demands attention in establishing a sound study 设立海事测量研究,需 要提醒人们测量系统包括设备,技术,环境和涉及的人。其中每 个因素(设备,估价师,样本,程序)的要求,注意在建立健全 学习

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Evaluation of 4 indexes from AIAG formulas: %EV – Equipment Variation – Repeatability 设备变奏-重复性 %AV –Appraiser Variation - Reproducibility 鉴定人变奏-重复性 %PV – Part Variation 部分变异 %TV – Total Variation 总变异

1. 2. 3. 4. „ „ „

NB Sum ot these indexes is NOT necessarily 100% 总结城市旅游局,这些指标并不一定是百分之一百


p MSA strategies: LAB ≠ IND „

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LABoratory approach (top-down, difficult), evaluation of measurement uncertainty, type A or B, distributions, formulas, GUM, etc... Ö QMSOFT is the right tool 实验室的方法 INDustry approach (bottom up, easy), assessment of %EV,%AV, %PV, %TV, using AIAG Ö GAGEpack is the right tool 业内办法


p GUM Workbench


p Uncertainty budget 预算的测量不 确定度


p Design of Experiments DOE „

Powerful tool for process improvement, analysing influence and relations between factors (speed, temperature, pressure, ...) 强大的工具,为工艺改进 ,分析影响和关系因素(速度,温度,压力, ... )


p Statistical Process Control SPC „

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Powerful tool for process control, to identify causes of variation 强大的工具,为过程控制, 以查明原因变异 X/s, X/R control charts, Pareto analysis 控制 图,帕累托分析


p Statistical Process Control SPC


q Research and Development „

China and EU can work together on R&D projects and reduce costs

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属于中国和欧盟科技研发框架项目,欧盟提供 50%的经费支持 Feanor provides assistance to Chinese companies to join CORDIS projects

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芬诺提供援助中国公司参加CORDIS FP7 研究计划


芬诺 刀具及测量仪研究发展有限公司 对于更多的问题.... „ „ „ „ „ „ „ „

电话:+39-3484121280 传真:+39-02700532664 手机:13717978084 网址:www.feanor.com MSN:info@feanor.com 贸易通:FEANOR E-mail: info@feanor.com 联系人:卢卡


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此项计划将削减您50%的研究和发展费用,我们的合作研究者在 航天,运输,纳米技术,新制造技术等。多项欧盟研究和发展项 目中同许多公司和研究所进行了全球性合作,如德国物理技术学 院和美国麻省工学院亦是我们的合作伙伴之一,芬诺公司期待在 中国找到合适的合作伙伴。项目共同开发下列项目: 1. 全息照相技术测量系统(OPTIGEW) 2. 直升飞机平面齿轮的研磨技术和齿轮传动装置的主要技术参数 测定(FACEGEAR) 3. 航天工业中转矩测量装置的标定 (CALTORQUE) 4. 大直径传动轴中外形参数和圆度测定(WINFORM) 5. 分析和校正参数齿轮 (TOPOFLANK)

PPT Presentation Feanor English-Chinese Software Measurement Laser Calibration软件度量激光校准  

PPT Presentation Feanor English-Chinese Software Measurement Laser Calibration 软件度量激光校准

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