Bharat Fritz Werner. Approach To Design and Develop Machine Tools Technologies and Composite Structures

Bharat Fritz Werner
Approach to Design and Develop

Machine Tools Technologies and
Composite Structures
By
Dr. Harshad Sonawane
Dr. Kalam Center for Innovation
BHARAT FRITZ WERNER LTD

Bharat Fritz Werner
A Journey Towards Excellence....
BHARAT FRITZ WERNER LTD 1

Strong Technical Foundation
1961: Technical and Financial Collaboration

with Fritz Werner Werkzeugmaschinen GmbH,
Berlin
1970: Partnership with Burckhardt & Weber,

Germany
1970-Present: Fully Indian owned company
2012: Acquired Matec Maschinen GmBH

Over the Past 57 Years
in
Machine Tool Industry
BFW’s Leadership Through Continuous and Vigorous
“New Product and Technology Development”
Efforts
Market Leader for Seven Consecutive Years in Horizontal

& Vertical Machining Centers and Special Purpose
Machines

Independent
BFW R&D Center
formed in
2014

2016

Formal Inauguration
February 2016
Formal Inauguration by
Shri. Kiran Kumar
Chairman,
Indian Space Research
Organization (ISRO)

Mission
Basic and
Applied
Research &
Development
Mission: Human Body Analogy
Skeleton Muscles Heart Brain Neural Health and

network Performance
*All figures are referred to google.com

Basic and Applied R&D in Machine Tools
Machine Tool Structures: Skeleton and Muscles

High Speed Motorized Spindles: Heart
Thermally Stable Spindles & Machines: Brain
CNC Systems and IoT based Management
platform: Neural Network

R&D projects at present
Project # 9001:
Alternate Materials
for Machine Tool
Project # 9002:
Structures
Development of
high speed high
accuracy
Project # 9001A: motorized Project # 9003:
Development of spindles Improving thermal
Epoxy Granite
Structure
stability of Project #9004:
BFW + Academia motorized spindles Development of
and complete CNC system and
Project # 9001B:
Development of machine IoT based
Composite CI
management
Structure
BFW platform

Project # 9001A:
Design and Development of Epoxy

Granite (EGTech) Machine tools

I: Raw Materials and Equipment
1. Granite slabs
4. Sieve 5. Granite particles
2. Stone crusher 3. Crushed slabs 6. Resin and Hardener
*Photograph courtesy PSG Tech, Coimbatore

III: Mould Preparation

II: Mixing, Pouring and Compaction
Granite particles
Pouring Vibrating table for compaction
Resin and Hardener Concrete Mixer Epoxy granite specimens

Mechanical Characterization: Test Setups
Compressive test Split tensile test Flexural test Damping test
Cast Iron:
0.001
Young’s Modulus: Epoxy granite:

0.02
Cast Iron (FG 300): Cast Iron:
960 MPa 135 GPa
Cast Iron:
Epoxy Granite: 300 MPa Epoxy Granite:
112 MPa Epoxy Granite: 30 GPa
28 MPa
Basic Research of Development of
Epoxy Granite is then Applied to
Manufacture VMC Machine Structures

VMC Column
Front Back Front Back
Cast Iron 3D Model Epoxy Granite 3D Model

Epoxy granite casting for VMC Column

VMC Base
Cast Iron 3D Model Epoxy Granite 3D Model

Epoxy granite casting for VMC Base

Project # 9001B:
Development of Composite Cast Iron

(iCTech) Machine Tools

Concept
Cast Iron Column Desired Composite Cast Iron

prototype characteristics of (iCTech) Column
iCTech material Prototype
Sound/Noise proof
Moisture resistant
Chemical resistant
Stiffness/weight
Excellent damping
Higher service life
Economical
Sustainable

iCTech: Iron Composite Technology*
Special Concrete Variety of Minerals Polymeric Resin and Micro-fillers

Hardener
Surfactants,
Wettability agents,
etc…..
iCTech Composite*
*Patented Technology
Experimental Performance Analysis
Prototype Samples Preparation
Cast Iron block iCTech block
Experimental Setup to measure natural frequencies of vibrations and damping
Impact hammer
PC
Accelerometer
Data logger
Free-free
hanging column
Comparison of Concrete with iCTech
(Concrete Column)
0.25 sec 0.25 s

(CI Column) 1.2X
improvement
0.3 s
(iCTech Column)
10.3X 0.029 s
improvement

iCTech Composite
Performance Testing for Full Scale VMC

Machine

Stiffness to Weight ratio for iCTechTM Solid Structure: S/W = 12.4
Improved by 4 times as compared to existing Cast Iron machines
(S/W=2.9)!
Appearance
of iCTech
VMC machine
(unguarded)

Performance of iCTech BMV 45+ Machine
Base Column Spindle Head
Existing Unfilled Cast Iron Structures
8X Improvement 3X
Improved Composite Cast Iron Structures
10X

Existing Cast Iron VMC Performance: Complete Machine
Existing VMC Machine
Radial Immersion Spindle speed: 1000 RPM Feedrate: 800 mm/min
EN 08 Steel
(45 HRc)
Machining Noise:
42-46 dB

iCTech VMC Performance: Complete Machine
Composite Cast Iron VMC Machine
Radial Immersion Spindle speed: 1000 RPM Feedrate: 800 mm/min
EN 08 Steel
(45 HRc)
Machining Noise:
32-35 dB
The
Machine
became 3X
Quieter

Performance Benefit of iCTechTM Composite Technology
• Upto 5X Vibration Damping & 4X Stiffness

• Upto 3X Longer Tool Life
• Upto 5X Higher Productivity and Surface quality using Stability Lobe
Diagram
• Easy to Machine Harder Materials (60 HRc)

Project # 9002:
Development of High-Speed High-

Accuracy Motorized Spindle

3D Spindle Layout

Design Consideration for Building Spindle
• Design of two plane balancing system

• Design of Air Oil lubrication supply to individual bearing
• Spring preload arrangement for bearings
• Effective cooling circuit to reduce thermal deformation

Dynamic Analysis of Spindle: 3D Model
Labyrinth Disc 2
Disc 1
Bearings Motor Rotor
Bearings
Spacers Lock nut Spacers Lock nut

Dynamic Analysis of Spindle: FEA
First order bending mode at 779 Hz Second order bending mode at 1520 Hz
Twisting mode at 2109 Hz Third order bending mode at 3428Hz
Longitudinal Elongation mode at 3752 Hz Fourth order bending mode at 4460 Hz

Project # 9003:
Intelligent Thermal Control of Spindle

and Machine

Background : What is thermal robustness?
Temp. change Thermal distortion of spindle Low accuracy
Ideal spindle Distorted spindle

Thermal robustness is achieved through three ways:
reduction, control and compensation
Three strategies:
1. Reduce thermal errors at source
2. Thermal error control
3. Thermal Compensation
• Intelligent Real-time Thermal Control (iRTC) module will use all three
strategies and will be deployed through iRIS

Thermal error reduction is achieved through a novel Spindle
Cooling Module (SCM)
• A novel cooling strategy called SCM is developed

• SCM balances the heat dissipation in spindle with the real-
time heat generation
• SCM significantly reduces thermal errors

Novel cooling results upto 50% reduction in thermal error

Compensation is performed using real-time information
The thermal distortion of a cutting point has got reduced by

more than 100% after compensation

A High-speed Die and Mould Series….For Excellent Performance!

BFW….A Leader in Innovation!

BFW….A Leader in Innovation!

Thank You!
Questions?
Reach us:
harshad.s@bfw.co.in
Mob: +91 9341 143 153

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Bharat Fritz Werner

Approach to Design and Develop

BHARAT FRITZ WERNER LTD

A Journey Towards Excellence....

BHARAT FRITZ WERNER LTD 1

1961: Technical and Financial Collaboration

1970: Partnership with Burckhardt & Weber,

1970-Present: Fully Indian owned company

2012: Acquired Matec Maschinen GmBH

BHARAT FRITZ WERNER LTD 2

Market Leader for Seven Consecutive Years in Horizontal

BHARAT FRITZ WERNER LTD 3

Dr. Kalam Center for Innovation

BHARAT FRITZ WERNER LTD 4

BHARAT FRITZ WERNER LTD 5

Skeleton Muscles Heart Brain Neural Health and

*All figures are referred to google.com

Machine Tool Structures: Skeleton and Muscles

BHARAT FRITZ WERNER LTD 7

BHARAT FRITZ WERNER LTD 8

Design and Development of Epoxy

BHARAT FRITZ WERNER LTD

4. Sieve 5. Granite particles

2. Stone crusher 3. Crushed slabs 6. Resin and Hardener

*Photograph courtesy PSG Tech, Coimbatore

*Photograph courtesy PSG Tech, Coimbatore

Resin and Hardener Concrete Mixer Epoxy granite specimens

*Photograph courtesy PSG Tech, Coimbatore

Young’s Modulus: Epoxy granite:

BHARAT FRITZ WERNER LTD

Cast Iron 3D Model Epoxy Granite 3D Model

BHARAT FRITZ WERNER LTD 14

Cast Iron 3D Model Epoxy Granite 3D Model

BHARAT FRITZ WERNER LTD 16

Development of Composite Cast Iron

BHARAT FRITZ WERNER LTD

Cast Iron Column Desired Composite Cast Iron

BHARAT FRITZ WERNER LTD 17

Special Concrete Variety of Minerals Polymeric Resin and Micro-fillers

Prototype Samples Preparation

Cast Iron block iCTech block

Experimental Setup to measure natural frequencies of vibrations and damping

0.25 sec 0.25 s

BHARAT FRITZ WERNER LTD 20

Performance Testing for Full Scale VMC

BHARAT FRITZ WERNER LTD 21

BHARAT FRITZ WERNER LTD 22

BHARAT FRITZ WERNER LTD 23

BHARAT FRITZ WERNER LTD 24

BHARAT FRITZ WERNER LTD 25

• Upto 5X Vibration Damping & 4X Stiffness

BHARAT FRITZ WERNER LTD 22

Development of High-Speed High-

BHARAT FRITZ WERNER LTD

BHARAT FRITZ WERNER LTD 26

• Design of two plane balancing system

BHARAT FRITZ WERNER LTD 27

Spacers Lock nut Spacers Lock nut

BHARAT FRITZ WERNER LTD 28

Twisting mode at 2109 Hz Third order bending mode at 3428Hz

Longitudinal Elongation mode at 3752 Hz Fourth order bending mode at 4460 Hz

BHARAT FRITZ WERNER LTD 29

Intelligent Thermal Control of Spindle