EUREKA PROJECT > 5783 ECOCAN
- SUMMARY
- OUTLINE
- PARTICIPANTS
-
F.Y.R. OF MACEDONIA
-
F.Y.R. OF MACEDONIA
-
SLOVENIA
-
F.Y.R. OF MACEDONIA
-
SLOVENIAINNOVATIVE ECO-FRIENDLY PROCESSING OF VOLUMETRIC SHEET METAL COMPONENTS
The project deals with optimisation of forming processes for sheet metal part production. Decrease of used energy and minimisation of environmental burdening are main objectives achieved by process design, material optimisation, increased adaptability of the tooling, and tribological conditions.
Status > ANNOUNCED - 21-Jun-2011 Technological Area Market Area Start Date > 30-Jun-2010 Duration > 36 Months Participating countries > SLOVENIA, FYROM | Main contactUNIVERSITY OF LJUBLJANA / FACULTY OF MECHANICAL ENGINEERING
Lakos PROF. KARL KUZMAN > HEAD OF FORMING LABORATORY Organisation type > University |
Project Description
The global production of volumetric sheet metal components could be estimated with some billions parts per day. Concerning the ecological impact of their production, transportation and end of use operations, the situation at the beginning of the next millennium is very anxious. As the spectrum of volumetric components like cans for food and beverages, containers for different liquids, volumetric parts for house hold appliances (refrigerators, washing machines, etc.) parts for personal cars and trucks is very broad and problems connected are very different, the project will be focused only on parts made from thin sheet metals. The major negative impacts of volumetric components on ecology and energy consumption could be structured as follows: 1. Material costs represent the biggest share of the final parts price therefore the material economy is the most important profit factor. 2. Material saving is also energy saving. 3. The ratio between the parts volume against its mass is very big, which means that long distance transportation could be questionable from high costs. 4. Deep drawing of sheet metals needs lubrication to reduce friction and to protect parts and tools surfaces. It is well known that conventional sheet metal forming processes are rigid, very difficult to be controlled in a real time. On a traditional way processes parameters are set on presses by experiences from material specifications of previous batches. To improve this situation the project aim will be to introduce innovative solutions as: * By systematic collection of material specification and process parameters of process failures or/and successful production a knowledge base will be designed. With the knowledge collected it would be possible to perform faster and more reliable process setting for a new sheet metal batch or to use it for process planning of a new product. * To design and evaluate intelligent metal forming systems consisting of sheet input control (thickness, strain hardening, anisotropy, grain size, etc.) connected to during the process adaptable press tools and in a real time quality control of products. All information will be elaborated in a real time and the system control unite could readjust process parameters or stop the production. * The use of more and more thinner sheet metals is a permanent goal therefore innovative solutions are more than needed. On the material side this could be realised by additional alloying of basic materials but this could have a negative impact on their formability. Shaping of very thin sheets could be done by hybrid processes combining rigid tools with compressed or exhausted air. * To study and implement new lubrication solutions. The best would be to do forming without lubricants by using combination of special coated tools with painted sheets. From the literature some research results are known that it is possible to combine lubrication with pure water or compressed air and vibrating tools. To realise stated goals the project consortium will be composed of parts producers, sheet metal producers, tool makers, press makers, designers of metal forming systems, experts for computer production control and quality assurance as well with some research institutions. Results and knowledge obtained by this project could also be implemented in other sheet metal forming processes. Project partners will therefore get a general overview about design and how to control complex production systems of volumetric sheet metal components with special emphasis on eco-friendliness and low energy consumption.
Technological Development Envisaged
Due to the immense cost pressure in sheet metal fabrication the entire production chain from the material supplier to the manufacturer of stamped parts need to decrease their costs. At the beginning of the chain, the steel producers need to produce the sheet metals, which just meet the technological demands for forming applications and are on the other side inexpensive enough for large volume production. The metallurgical improvements of the materials without increase of production costs will be sought to improve their mechanical tolerances. The part development in digital environment is nowadays common optimisation tool. However, existing CAE (Computer Aided Engineering) optimisation tools does not support energy consumption oriented part development being interesting when large volume like household appliances are produced. In the project developed decision-making system will be supported by numerical simulations of forming process for each particular developed part. The optimisation methods like experimental design method, surface response method and variance analysis are widely used in analyses of forming processes and they will be implemented also in proposed optimisation system. However the optimisation tools currently does not support features for minimisation of energy consumption in forming processes what brings developed optimisation system technological advance and innovation potential in comparison to other optimisation tools. The mechatronic systems for the sheet metal forming tools are not well developed and are still unknown area of technology. Therefore in the project a lot of work on the field of integration of different pressure, friction, temperature sensors for the activation of temperature and vibration actuators are to develop. These two types of actuators will help toolmakers to enlarge the processing window for the sheet metal forming. With the implementation of mechatronic systems (sensors, actuators and logic), the production process will be much more stable and it will allow us to produce products with thinner material, what will bring benefits in the price/product ration. Due to the input from the sensors, the process will be controlled with the temperature actuator and the force (vibration) oscillator. This will allow the material in the forming process to flow much more smoothly into the die. Also less wrinkling of the material is foreseen. In modern industrial tools various lubrications systems like oiling, spraying, spatial adaptive spraying, hard coating of tooling, proper material selection at tool-workpiece interaction, etc. are used. Furthermore, some applications of high-pressure lubrication aiming the improved material flow in the flange of deep drawn parts as well as heating of the flange area are known. However the implementation of pressurized pneumo-trybological systems represents promising technological innovation.
Main contactRade Koncar-TEP Mech. Eng. Zarko Georgievski > Head of technical department Organisation type > SME |
Contribution to project
The organisation has a experience in sheet metal processing, production of various parts from sheet metal by cutting, punching, bending, welding and electrostatic painting. RK-TEP will participate in research part of project and implementation of the project results.
Expertise
The core business of RADE KONCAR-TEP is production of metal enclosures, distributive oil transformers, transformer substations, connecting and measuring-transfer boxes, low voltage boards, designing complete projects, mounting, testing and putting into operation low, mid and high voltage complex objects. Also RK-TEP has a large experience with production of thin sheet metal packing. RK-TEP will contribute to the project research areas with the large experience based on the knowledge combined with a long term practice.
Main contactLIV HIDRAVLIKA IN KOLESA, proizvodnja, predelava in trgovina, d.o.o. M.Sc. Robert Ivancic > Project Manager Organisation type > R and D Performing SME |
Contribution to project
The contribution of LIV HIDRAVLIKA IN KOLESA team will be study taking into account all conditions in the process. The project has three specific aims: 1. Study the influence of material anisotropy on the size of the bur, which appears on a section of a strip of sheet metal; 2. Study the impact of speed of movement ram presses on the wall thickness; 3. Facilitate zero defect production with optional data assimilation and scenario analysis capabilities.
Expertise
The core activity of the company LHK are development, construction and design of products made of metal or plastic materials, development and design of appropriate production and assembly technologies to achieve the product's characteristics, manufacturing of metal products and products made of plastics and final assembly of the products. Other activities in the company LHK are coating of metal products, cutting of metal products, blasting and welding. Core and other activities are performed in two profit centres (Profit centre Hydraulics and Profit centre Wheels and castors) at three locations (Postojna, Hrusevje, Osilnica). For implementation of our activities we have at disposal appropriate human resources, knowledge, technologies and infrastructure. Management of the activities in the company LHK is provided by established quality assurance system according to standard ISO 9001 and environmental management system according to standard ISO 14001.
Main contactArcelorMittal Skopje Mr. Nikola Nikolovski > CEO Technical Assistant Organisation type > Large company |
Contribution to project
Our contribution would be in sharing experience from the field of production of steel strip, meaning production processes, potential areas of improvement, issues, etc. Also our facilities could provide test production of the thin strip in line with the ongoing research. ARCELORMITTAL GROUP has an R&D centre which could be of some assistance during this project.
Expertise
LNM adds to its downstream activities in the Balkans with the acquisition of hot and cold rolling mills in Skopje, Macedonia from Balkan Steel. The two mills, dormant for two years, are renamed Ispat Skopje. The hot strip mill has a capacity of 1.2 million tonnes a year, the cold rolling mill a capacity of 1 million tonnes. The acquisitions further strengthen the Group's position as the leading steel producer in Central and Eastern Europe. The facilities are subsequently renamed MITTAL STEEL SKOPJE. Our core business is production of Hot Rolled, Cold Rolled, Hot Dip Galvanised and Organic Coated strip. These products are manufactured in our two facilities Hot Rolling Mill and Cold Rolling Mill. Parts of our organisation are experienced metallurgy, electrical and mechanical engineers who make sure that the processes in the mills are at top notch level and according to the customer's requirements.
Main contactGORENJE ORODJARNA, D.O.O.
Dr. Blaz Nardin > General Manager http://www.gorenje-orodjarna.si Organisation type > Large company |
Contribution to project
The organisation is the biggest tool and mould making company in SLOVENIA. It has more than 13 million EUR annually turnover in year 2008. In GORENJE ORODJARNA, D.O.O. there are more than 200 employees, with more than 30 people employed in the operative R&D department. GORENJE has 50% more incomes than other toolmaking companies in Slovenia. It has estimated 30% market share of all produced tools in Slovenia. The role of the company will be co-operation on followed activities: 1. Technology determination; 2. Preparation of the demonstrator; 3. Integration of the mechatronic systems into the sheet metal forming tool; 4. Dissemination of project results; 5. Exploitation of project results. The R&D team from GORENJE will focus on the industrial dissemination of the project results. The organisation has strength and knowledge in the field of toolmaking and mechanical engineering.
Expertise
GORENJE ORODJARNA, D.O.O. is a tool and mould making company, producing tools for sheet metal forming, plastic injection moulding, thermoforming and Styrofoam packaging (PS packaging). In the last years we have specialised for the high complex tools for injection moulding, mainly used in the household appliance industry. GORENJE ORODJARNA D.O.O., has 220 employees and is 100% owned by the GORENJE D.D. The strategic orientation of the organisation is in the household appliance industry and automotive industry and therefore the project topic is very important for the company. Product quality is ensured at all stages of the business process: from quoting, design, technology, machining to final assembly and servicing. GORENJE ORODJARNA operates to the quality standard ISO 9001:2008 (International Standards Organisation), and the corporate environmental policy is consistent with the requirements imposed by ISO 14001:2004 requirements. The company has also acquired the occupational health and safety certification OHSAS 18001:2007. Gorenje Orodjarna is a member of the Slovenian Tool and Die Development Centre and a member of the Automotive Cluster of Slovenia. At GORENJE ORODJARNA we use numerous processes in tool making: milling, grinding, drilling, turning, WEDM (Wire Electrical Discharge Machine) and EDM (Electrical Discharge Machine), measurements and laser processing. For each and every process, GORENJE ORODJARNA has highly skilled staff and matching technological equipment, which is further complemented by tool testing machines such as hydraulic and mechanical presses, and a five-axial laser centre. In the last years we have specialised for the high complex sheet metal tooling, mainly used in the household appliance and automotive industry. GORENJE ORODJARNA D.O.O. has 211 employees and is 100% owned by the Gorenje d.d. The strategic orientation of the organisation is in the household appliance industry and therefore the project topic is very important for the company. GORENJE ORODJARNA, D.O.O. successfully implemented different R&D projects in the past and it is also now actively involved in various R&D national and international projects.
Main contactUNIVERSITY OF LJUBLJANA / FACULTY OF MECHANICAL ENGINEERING
Lakos PROF. KARL KUZMAN > HEAD OF FORMING LABORATORY Organisation type > University |
Contribution to project
The university has in the project the leading role as R&D performer by setting-up the system for selection of environmental-friendly forming process parameters ranging from the selection of forming stages and their intermediate shapes, various lubrication types, innovative principles for minimisation of used lubrication, etc. In the Forming Laboratory following tasks will be performed: * Mechanical analyses of sheet metals and determination of their formability limits; * Set-up of database for proposed materials determined by other partners (in particular companied dealing with mass production); * Development of new technological concepts needed for minimisation of spread of mechanical propertied of sheet metal; * Determination of crucial input process parameters at sheet metal forming influencing the part quality; * Cooperation on tribological analyses needed for minimisation of used lubricants; * Cooperation on development of new tribological concepts aiming the omitting of lubricants; * Analyses of concepts for minimisation of used forming energy by optimisation of forming process; * Set-up of decision-making system supporting the toolmakers by selection of optimal forming stages; * Cooperation with toolmakers on development of flexible tooling systems; * R&D support for companies producing sheet metal parts.
Expertise
The UNIVERSITY OF LJUBLJANA (UL) is a public autonomous educational, scientific research and artistic institution of higher education consisting of 26 members: 23 faculties and three academies. The scientific reputation of the UNIVERSITY OF LJUBLJANA can be measured on the world ranking lists where it ranks among the top 500 universities according to the ARWU (Academic Ranking of World Universities) Shanghai ranking and the British newspaper The Times. According to the Spanish Webometrics, the UL takes 124th place out of 4,000 European universities, which puts it in the top 4 percents. Currently UL employs 6,062 employees from which 3,196 are teaching and assistant staff being very active also in their research fields, 415 full time researchers and 516 junior researchers. Other employees are professional, technical and administrative staff. Research activity at the UL takes place in 270 research groups with over 3,400 certified researchers. The researchers have worked on 144 research programmes, 153 fundamental projects, 158 applicative projects and 33 post-doctorate projects, on 179 CRP targeted research programmes and on 879 other projects. With ninety-year tradition of high quality research the institution is able to perform projects of the highest quality and at the highest level. In the past decades several research connections were established all over the world and the establishing of new scientific connections and co-operations is continuous process. Through this connections the research and teaching staff of the University was invited to co-operate and coordinate various European projects ranging from the FP6 calls (117 projects) and FP7 calls (52 projects), numerous bilateral co-operations with research institutions all over the world, educational projects financed by European union (TEMPUS, ERASMUS; Leonardo da Vinci, DAPHNE, SafeInternet, eLearning, eTEN, Lifelong Learning Programme and many more). The co-operation with industry is strong supported by several EUREKA projects and projects financed by Structural Funds in SLOVENIA (ERDF, ESF, EQUAL, INTERREG). FACULTY OF MECHANICAL ENGINEERING has beside its primary teaching position also important role in the scientific and research area. The Faculty as one of the members of University of Ljubljana was implemented in numerous above mentioned university research actions on the national, European and worldwide calls. The intensive cooperation in research projects can be presented from the income of the institution where almost a half of turnover comes from the research area. The Forming Laboratory as a unit of Department of Manufacturing Technologies and Systems of Faculty of Mechanical Engineering is well reputated research group who participated in several national and international research projects, bilateral co-operations with various European countries (CZECH REPUBLIC, SERBIA, HUNGARY, etc.). The last bilateral cooperation was approved at the end of 2009 with Faculty of Mechanical Engineering Skopje who is partner in the proposed project. Furthermore, strong industrial support is provided by numerous industrial projects, which are either partial co-funded by Slovene government or international funds. In particular was Laboratory active in the frame of EUREKA calls in the last 5 years six projects were successfully finished. The project E! 2819 FACTORY ECOPLAST was also selected as success story from the EUREKA.
Main contactFaculty of Mechanical Engineering / University Ss Cyril and Methodius Ph.D. Jasmina Caloska > Associate professor Organisation type > University |
Contribution to project
The organisation (FME) will participate in the project as research partner involved in the following tasks: 1. R&D work on the field of determination of optimal technological parameters in the process of deep drawing to the order reduce of material consumption and influence on the product quality. 2. Dissemination of project results through workshops and seminars which will be organised for SMEs, diploma and master works of our students. 3. Exploitation of project results - Macedonian companies will use the results for cans and other products from thin sheet metals, tools design, choose of optimal lubrication to reduce friction and protect parts and tools surfaces. Using the appropriate material, tool and optimal technological parameters the companies will get material and energy costs savings as a competitive advantage.
Expertise
THE FACULTY OF MECHANICAL ENGINEERING SKOPJE (http://www.mf.ukim.edu.mk), at the University of "Ss. Cyril and Methodious" is one of the largest University institutions in the REPUBLIC OF MACEDONIA. It has already entered the last decade that will bring them to the jubilee-half a century of its existence. Since its modest beginning in 1959, until today, the Faculty has grown into an internationally acknowledged and respected education and scientific institution. The Faculty continuously maintains, enriches and deepens the cooperation with numerous educations, scientific and economic institutions and other partners from the country, region and the world. The Faculty has six institutes and one department, as follows: Institute of Production Mechanical Engineering with 5 laboratories; Institute of Mechanical Construction, Mechanisation Machines and Vehicles with 3 laboratories; Institute of Thermo technology and Thermo-energetics with 5 laboratories, Institute of Hydro-technology, Pneumatics and Automatics with 2 laboratories; Institute of Welding and Welding Constructions with 4 laboratories; Institute of Mechanics with 1 laboratory and a Department of Mathematics and Information Technology. The Institutes are further divided into many well-equipped chairs and laboratories or working groups. Each Institute is chaired by a professor, who is responsible for its operation and high level of academic and professional conduct of its members. With the Faculty, there are also the IT (Information Technology) Centre and General services, as separate units. The Faculty of Mechanical Engineering offers postgraduate - master studies of Science in Mechanical Engineering in full time studies (1 year) in nine postgraduate study programs and part time studies (2 years) in six postgraduate study programs. The Faculty offers doctoral studies for Ph.D. in Technical Sciences. The FME's role is: to implement the developed teaching content of the full time postgraduate studies, to update the laboratories with the new teaching and communication equipment, to develop and conduct the LLL courses, to disseminate the results of the project and to ensure the sustainability of the project. One of the principal activities that the Faculty has nurtured from its beginning is its applicative, activity, which is applicable and short-term in its character. It embraces a number of Mechanical Engineering technical questions, and numerous material production organisations take part in it as partners. The key researcher within proposed project will be Dr. Jasmina Caloska. Her research fields are metal forming processes, tool design, production and service systems, numerical simulation, CAD (Computer-Aided Design), CAE (Computer Aided Engineering), CFD (Computational Fluid Dynamics) technology, quality systems, etc. and she also has a great experience with R&D projects. Additionally active participation is expected of Dr. Atanas Kocov and Dr. Jovan Lazarev, who are experts also in the field of metal forming technologies, composite materials, die design, CAD and CAE. Key references of the R&D: 1. J. Lazarev, J. Caloska, A. Kocov: Investigation of deformability of cold formed sheet metals; Ministry of Education and Science; 2005. 2. J. Caloska, A. Kocov, I. Lazarev: Metal matrix composite for tools resistant of attrition, Ministry of Education and Science and MKMold DOO- Ohrid, 2007-2008. 3. A. Kocov, J. Caloska: Function of the numerical simulations in the competitive engineering. Scientific-research project between Ministry of education and science of Republic of Macedonia and Ministry of Education and Science of Republic of Slovenia, 2006-2009. 4. J. Caloska, A. Kocov, I. Nasev: Systems for assessment of surface integrity; EUREKA project, partners: Gorenje,Slovenia; TECOS, Slovenia; AITIIP Foundation, Spain; DESARROLLO EMBEL SL, Spain; CIRKO Macedonia, Solar Tubes Macedonia, 2007-2010.