Productivity, quality & efficiency & efficiency increase - - PowerPoint PPT Presentation

Productivity, quality & efficiency & efficiency increase in high temperature processes

• J. Demmel, 7th Nov. 2011

• 1. Introduction: Singularities of High Temperature Processes
• 2. New Materials innovate HT-Processes

Contents

• 3. Applications of new CFRC-racks in HT-Processes
• 4. Automation of Handling in HT-Processes
• 5. Integration of HT-processes in the Production chain
• 6. References and Contact

• J. Demmel, 7th Nov. 2011
• 6. References and Contact

• 1. Singularities and Importance of High Temperature Processes

High Temperature => hardening, brazing, sintering, CVD Processes => permanent temperature > 500°C (932°F)

Quality Cos ts

HEAT TREATMENT PROCES S

SOFT MACHINING HARD MACHINING

• J. Demmel, 7th Nov. 2011

Delivery reliability Production requirements

• 1. Singularities and Importance of High Temperature Processes

Execution time in a range of hours or in a range of

HEAT TREATMENT PROCESS OTHER MANUFACTUR E PROCESSES

Execution time Degree of reaction Maintenance Productivity increase through inves tment in a range of hours or days in a range of s econds or minutes s low because of the long s et up and proces s time rapid, short term high inves tment for new equipment, however s mall lead time reduction through medium investment significative performance increas es can be achieved duration of days

• r weeks

because of the furnace the machines can be

• J. Demmel, 7th Nov. 2011

Cost s tructure Maintenance and repair because of the furnace cool off and heat up time almost all costs are fix costs (3-4 working shifts) most of the costs are variable costs (1-3 working s hifts ) the machines can be repaired in a short time

• 2. New Materials innovate HT-Processes

The Nailable Ceramic CFRC: Carbon Fibre Reinforced Carbon

• J. Demmel, 7th Nov. 2011

Reinforced Carbon

Stress-Strain Curves

(Source: Petzow, G., 1988)

• 2. New Materials innovate HT-Processes

Density

6 8 10 density [g/cm³] 20°C

Specific Strength

150 200 250 strength / density [N m / g] 20°C 1000°C

2 4 2D-CFC heat resistant steel Inconel 600 ODS- Superalloy density [g/cm³] 1000°C

Strength

300 400 500 600 yield strength Rp0,2 [N/mm²] 20°C 1000°C

50 100 2D-CFC heat resistant steel Inconel 600 ODS- Superalloy strength / density [N m / g] 1000°C

Coefficient of Thermal Expansion

10 15 20 K-1]

• J. Demmel, 7th Nov. 2011

100 200 2D-CFC heat resistant steel Inconel 600 ODS- Superalloy yield strength R 1000°C

• 5

5 10 2D-CFC heat resistant steel Inconel 600 ODS- Superalloy C.T.E. [10-6 K 20°C 1000°C

• 3. Applications of new CFRC-racks in HT-Processes

Vacuum brazing racks

• Comp. Modine,

2 plants in Germany

 Results for our customer:

• Increase in loading capacity of 50 %
• Improvement of handling

Situation before

2 plants in Germany

• Improvement of handling
• Enhanced product quality
• Profitability (amortization ~1 year)

• J. Demmel, 7th Nov. 2011

• 3. Applications of new CFRC-racks in HT-Processes

New CVD-rack

• Comp. TTC,

Barcelona, Spain Barcelona, Spain

 Results for our customer:

• Less distortion of the parts
• Less energy consumption
• High Profitability

• J. Demmel, 7th Nov. 2011
• High Profitability

Annealing Racks (with oil quenching)

• 3. Applications of new CFRC-racks in HT-Processes

 Results for our customer:

• Increase in loading capacity of approx. 70 %
• Improvement of handling

quenching)

• Comp. Wiha, Germany

Situation before

• Improvement of handling
• Enhanced product quality (less distortion)
• Profitability (amortization ~1,2 years)

• J. Demmel, 7th Nov. 2011

• 4. Automation of Handling

Automatic Furnace Feeding Furnace Feeding

• Comp. Lemken,

Germany

Results for our customer:

• Ergonomic working conditions instead of heat

and manual handling of work-pieces weighing up to 20 kg

Situation before

• J. Demmel, 7th Nov. 2011

up to 20 kg

• Flexibility (> 50 products) and profitability

• 5. Integration of HT-processes in the Production chain

INTEGRATION LEVELS OF HIGH TEMPERATURE PROCESSES IN THE PRODUCTION CHAIN

Hard machining Heat treatment & maching

material flow and process integration

Heat treatment Soft machining Hard machining Heat treatment Soft machining Hard machining Buffer Heat treatment Soft machining Hard machining

material flow integration but no process integration

• J. Demmel, 7th Nov. 2011

Workshop B Workshop A Workshop A Heat treatment Soft machining Hard machining

no integration

• 5. Integration of HT-processes in the Production chain

S

• ft machining

Heat treatment Hard machinig

PR ODUC TION C APAC ITY

S

• ft machining

Heat treatment Hard machinig

P R ODUC TION C APACITY maximum capacity real capacity A A-Teile A

C APAC ITY PR ODUC TION S EQUE NCE maximum capacity real capacity

P R ODUC TION S EQUENC E B C A B C B C

OUTS OR C ING

S

• ft machining

Heat treatment Hard machinig

P R ODUC TION C APACITY maximum capacity real capacity

• J. Demmel, 7th Nov. 2011

S EQUE NCE

P R ODUC TION S EQUE NC E

• 6. References and Contact

References CFRC racks

Herzog, Germany Realisation of CFC-carriers for the carburisation (oil) of drive elements Hilti, FL & USA CFC-rack for the vacuum hardening of drills MAN, Germany Planning of optimised charge carriers for gearwheels and pinions MAN, Germany Planning of optimised charge carriers for gearwheels and pinions Modine Europe Realisation of CFC-carriers for vacuum brazing of heat exchangers Philips, Netherlands CFC-rack for the vacuum annealing of tools NN1, Great-Britain Realisation of CFC-carriers for vacuum process for aviation engines TTC, Spain CFC-carrier for CVD-coating Wiha, Germany Realisation of CFC-carriers for the Annealing (oil) of allen keys CFC-racks for case hardening (oil) of stabilizers for cars

• J. Demmel, 7th Nov. 2011

NN1 , Germany CFC-racks for case hardening (oil) of stabilizers for cars Pratt & Whitney, Canada Realisation of CFC-rack for the vacuum process (with partner)

1 Projects and/ or names of our customers can not be quoted because of a non-disclosure agreement.

• 6. References and Contact

References Heat Treatment & Production

Braun (Gillette), Germany Automatic loading of continuous furnaces with parts Durotec Planning of an automatic loading device for heat treatment fixtures for driving shafts for driving shafts Huawei, China Development of a handbook for production development according to DFA and DFM regulations Lemken, Germany Automation of handling of plough components in heat treatment installations MAN, Germany Implementation of improved production processes between soft treating and hard treating NN1 Automatic feeding & handling of parts for continuous furnaces Wiha, Germany Automatic feeding and handling of hexagonal allen keys by means

• J. Demmel, 7th Nov. 2011

Wiha, Germany Automatic feeding and handling of hexagonal allen keys by means

• f a SCARA robot

1 Projects and/ or names of our customers can not be quoted because of a non-disclosure agreement.

• 6. References and Contact - Development

Fraunhofer Technology Development Group Nobelstraße 12, D-70569 Stuttgart Dipl.-Ing. Jörg Demmel Telephone: +49 (0) 711/970-3621 Telephone: +49 (0) 711/970-3621 Facsimile: +49 (0) 711/970-3998 Email: joerg.demmel@teg.fraunhofer.de Internet: http://www.teg.fraunhofer.de Department: Production Processes Group:

• J. Demmel, 7th Nov. 2011

Group: Production Engineering, Application of New Materials

• 6. References and Contact - Sales with our Co-operation

Toyo Tanso USA: Sales Area‘s & Sales Person‘s

• J. Demmel, 7th Nov. 2011

Mid-Atlantic DOUG GARDA Phone : (412) 921-1407 Fax: (412) 921-4030 email : dgarda@ttu.com Northwest TOM STORMS Phone : (503) 661-7700 Fax: (503) 669-9107 email : tstorms@ttu.com Southwest LOWELL JOHNSON Phone : (972) 434-8117 Fax: (972) 353-4322 email : ljohnson@ttu.com East Coast JACK VITALE Phone : (508) 528-4969 Fax: (508) 541-7437 email : jvitale@ttu.com