Klimczyk Institute of Advanced Manufacturing...

FP7 NMP/INCO Brokerage Event

Warsaw, 17-18 September 2009

THE INSTITUTE OF ADVANCED MANUFACTURING TECHNOLOGY

The Institute of Advanced Manufacturing The Institute of Advanced Manufacturing TechnologyTechnology

37a Wroclawska St., 30-011 Cracow, Poland

www.ios.krakow.pl

Department of Materials EngineeringDepartment of Materials Engineering

Piotr Klimczyk

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- The Institute of Advanced Manufacturing Technology is a research center with over 50 years of experience in solving complex scientific and technological industry-related problems.

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The main areas of our activity:

• material technology

• technical metrology

• manufacturing technology

• techniques of metal cutting

• abrasive and erosion machining

• assembly and automation of manufacturing processes




Electrodischarge machinesTypical machined objects are: forms for plastics, forge dies, cast modules, drawing dies, blanking dies.




EDM wire cutting machine

Applied mainly in tool-rooms producing blanking dies, press-tools and forms for production of cutting elements for cutting out tools - especially for concurrent machining of cooperating parts, for instance cutting plates, guiding plates, pushing devices etc.

EWEB 40 CNC




Production lines




Tools for burnishing

Burnishing is the chipless, finishing, cold machining of the surfaceapplied to steels, cast steel, copper alloys, aluminium alloys, cast iron and other metals




Special hobbing cutters

Due to constructional solutions, tool materials and application hobbing cutters made by IOS are the special tools designed to particular technological job.




Universal boring and facing heads

12605 - K/200, K/400, K/500




Diamond and CBN grinding wheels with resinous, metallic or ceramic bond

Grinding wheels with diamond grains - for sharpening and lapping sintered carbide tool blades, surfaces or internal grinding as well as for semiconductive ware, synthetic and natural gem stones, concrete, granite and marble. Wheels with CBN grains - to grind tool steels, high-speed steels and other hard to machine alloy steels of high hardness.




LINEA NMP series co-ordinate measuring machines

The machines are used for absolute length measurements in 3D co-ordinate. They are useful in dimensional control of machine elements or complex shapes and large dimensions.

LINEA NMP




Profilometers

For measurement and analysis of surface roughness, waviness and profile without filtration, it is the laboratory instrument equipped with computer and also 2D and 3D analysis program giving the possibility to evaluate geometric structure of a surface in a complex way.

PM-02M

Portable instrument for industrial measurement of basic roughness parameters.

TOPO L50




Department of Materials EngineeringDepartment of Materials EngineeringPreparation

Investigation & Application




The main research areas

• Different kinds of advanced materials : ceramic materials, superhard composites (diamond and cBN with different bonding phases), nanomaterials

• Conventional and unconventional methods of sintering : pressureless sintering, vacuum, Ar, N2, HPHT, quite soon: SPS, MW

• Materials investigations :• structure, phase and chemical analysis (optical

microscopy, SEM, EDS,WDS, EBSD)• physical and mechanical properties (density, elastic

constants, hardness, fracture toughness) • technological tests (high temperature wear tests,

cutting tests,




Cutting inserts

Superhard compositesCeramic grades

AI2O3 + ZrO2pure AI2O3, (AI2O3 + TiC) (AI2O3 + TiC + TiN)

Diamond or cBN + ceramic or metallic binding phases




The recent (2008) innovative work “Diamond composite and method of its obtaining”received a gold medal in Brussels at the Belgian and International Trade Fair for Technological Innovation “EUREKA”.




Homogenization and compaction of powders by conventional and unconventional methods




Sintering equipment: from vacuum to ultra HPHT




pmax=8 GPa

Tmax=2400 oC

HPHT equippement with Bridgman type toroidal anvils and computer control system




Quasi hydrostatic distribution of pressure




0 10 20 30 40 50 60 70 800

1

2

3

4

5 P (Power of heating)

T [s]

P [k

W]

0

1

2

3

4

5

R (Resistance)

R

Sintering process takes only few minutes !!!

HPHT sintering




Materials research laboratory




Research Projects carried in contribution of IOS

• CRAFT PROJECT – ELESIN Electrochemical-erosion sinking process for high precision hole production GIST-CT-2002-50176 – Co-ordinator: United Kingdom

• GROWTH Research Project - SPECTRUM Super Precision Electro-Chemical machining Technology including ncluding Rec ycling of Usable Materials G1RD-CT-2000-00421 – Co-ordinator: PHILIPS and then IOS

• INCO- COPERNICUS , concerted Action Contract IC15-CT9 8-0801Research on clean hybrid micromachining (HMM) proces ses,cordinator: IOS

• STREP – NAMAMET Contract NMP3-CT-2004-001470

Processing of NAnostructured MAterials through MEtastableTransformations coordinator: Politecnico di Torino, Italy

• STREP – E4 EC Contract No. 027282 Extended Enterprise Management in Enlarged Europe , coordinator: Centro Ricerche Fiat




NAMAMET“Processing of NAnostructured MAterials through MEtastable Transformations” , Contract No. NMP3-CT-2004-001470

6th European Framework Programme, Priority 3(Nano-technologies and nano-sciences, knowledge-based multifunctional materials, and new production processes and devices)




Participant name Participant short name Country

Politecnico di Torino POLITO Italy

Consiglio Nazionale delle Ricerche,

Institute for Energetics and Interphases CNR–IENI Italy

Università di Cagliari UNICA Italy

Instituto de Ceramica y Vidrio ICV–CSIC Spain

Instituto Nacional de Engenharia

e Tecnologia e Innovaçao INETI Portugal

Universitat de Barcelona UNIBA Spain

Institute of Metal Cutting IOS Poland

Technical University of Darmstadt TUD Germany

Centre National de la Recherche Scientifique CNRS France

University of Hertfordshire UH UK

Talleres Mecanicos Comas TMC Spain

Tecnologia e Engenharia de Materiais TEandM Portugal

Université de Technologie de Belfort Montbéliard UTBM France

Universities + Institutes + Enterprises = Consortiu m




Different systems, different form of materials, one idea

Al-Ti-O (Al 2O3–TiO2)

Al-Nb (NbAl 3)

Ti-B-C (TiC–TiB 2)

Al-Zr-O (ZrO 2–Al 2O3 )

Ni–Ti (NiTi SMAs)

Systems

Final forms of material

�� Coatings�� Free standing coatings

„Direct bulks”�� Bulks (different methods of

densification)

Ti-Al-C-O (Ti–TiC-Al 2O3)




SHS + Rapid cooling

(Self-propagating High-temperature Synthesis)

Mixture of reagents: 6Ti + B4C + 1.8C

Metastable, composite powder

Example: metastable powders densified by HPHT

HPHT sintering

Densified material

Metastable nanopowder production (POLITO, UNIBA)

HPHT densification (IOS)

APS + Rapid cooling

(Atmospheric plasma spray)

Mixture of initial powders: ZrO 2 + Al 2O3

Metastable, composite powder

TiC1–x – 33mol%TiB 2 ZrO2 – 20wt.% Al 2O3




Sintered compacts

Directly after sintering After grinding process

HPHT sintering method is effective in inhibiting of the grain growth of ceramic composites

TiC1–x – 33mol%TiB 2

ZrO2 – 20wt.% Al 2O3




More details on our website:

www.ios.krakow.pl

Thank you for your attention!

Klimczyk Institute of Advanced Manufacturing...

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