Advanced Hybrid Mechatronic Materials for ultra precise and high performance machining systems design

Fabrizio Meo^a, Angelo Merlo^b, Maria de la O Rodriguez^c, Bernhard Brunner^d, Massimo Ippolito^e

^aFidia S.p.A., Italy

^bCe.S.I. Centro Studi Industriali, Italy

^cFundacion Fatronik, Spain

^dFraunhofer Institut Silicatforschung, Germany

^eSequoia Automation srl, Italy

Materials used for machine tool building: cast iron, welded steel, aluminium-alloy

Machine dimensions: from 600*400*400 mm to 2000*1000*1000 mm

Machine axis Acceleration: 10-15 m/s2

Machine axis Speed: 60-100 m/min

Machining Accuracy due to dynamic performances: 10-50 micron

Machining Accuracy due to deformations: 10-300 micron

Noise emission: about 75-78 dBa.

Machine axis Acceleration: 3-5 times higher

Machining Accuracy: 0.5-1 micron

Achieved through:

• Reduction of Vibration in a low frequency domain (0-50 Hz)
• Reduction of Vibration in a high frequency domain (50-1000 Hz)
• Reduction of structural displacements due to thermal effects or elastic deformations

1. Strong mass reduction of mobile machine parts
2. Ultra light structure with ability to change damping and stiffness characteristics

• polymeric composite materials fibers reinforced (CFRP) material, using carbon fiber and epoxy matrix;
• sandwich (pyramidal core) construction consisting of prismatic core and steel skins

• Tuned absorbers

• Smart platform

Future developments

In the prosecution of the research work, it is envisaged to generate, on the basis of the available points cloud a b-spline surface by a real-coded-genetic algorithm. The availability of an optimized continuous surface will make it possible to realize an adaptative control of the too trajectory to minimize the machining errors.