WHO IS IRUBA INNOVATIONS? ® WHO IS IRUBA INNOVATIONS? INNOVATIONS & IDEAS RUTSCHINSKI MATTIAS - Face and CEO BAUER JOACHIM – Tool head and CEO PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 1

WHO IS IRUBA INNOVATIONS? ® WHO IS IRUBA INNOVATIONS? Founded 1. August 2009 -GbR / 2013 -GmbH Tools are only made at the J. Bauer GmbH Specials are our specialty (accuracy / design/ form) IRUBA offers solutions 2012 start of strong collaboration with DPS (Delcam professional services UK) - 2014 several new Partner to complete solutions PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 2

INNOVATIVE GREEN TECHNOLOGY ® INNOVATIVE GREEN TECHNOLOGY MANUFACTURING OF FIR-TREE-ROOT NOTCHES GERMAN ENGINEERING / PATENT TOOLS MADE IN GERMANY CARBIDE MADE IN GERMANY GERMAN SUPPORT WORLDWIDE REMANUFACTURING OF TOOL IN GERMANY PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 3

NEW WAYS BETTER SOLUTIONS INNOVATIONS NEW TECHNOLOGIES ® NEW WAYS BETTER SOLUTIONS INNOVATIONS NEW TECHNOLOGIES PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 4

THE IDEA FOR THE NEW TECHNOLOGY ® THE IDEA FOR THE NEW TECHNOLOGY 1. 2. 3. PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 5

BASICS OF THE NEW TECHNOLOGY ® BASICS OF THE NEW TECHNOLOGY A ROUGHING OPERATION - WITH HIGH THERMAL DEVELOPMENT - BIG CUTTING FORCES - LOW CHIP-REMOVAL-RATES WILL CHANGE INTO A „FINISH OPERATION“ - WITH LOWEST THERMAL DEVELOPMENT - LOW CUTTING FORCES - HIGH CHIP REMOVAL RATES PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 6

BASICS OF THE NEW TECHNOLOGY ® BASICS OF THE NEW TECHNOLOGY Special carbide end mill Low cutting forces, almost no thermal development on the cutting edge Interpolating high performance cutting with only “3“ levels Open the slot -and put in the undercut geometry, will be performed in one single step PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 7

FIR -TREE -ROOT NOTCHES ® BASICS OF THE NEW TECHNOLOGY Interpolating by HPC to manufacture notches on a rotor Straight notches, Ankle notches, Radius notches, Always rough-milling without full enlacement END -MILL FIR -TREE -ROOT NOTCHES PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 8

BASICS OF THE NEW TECHNOLOGY ® BASICS OF THE NEW TECHNOLOGY Advantages: 1. Highest process safety 2. No thermal contribution into boundary layer of work piece 3. Lowest cutting forces (low KW 4. Low amount of carbide special tools 5. High chip removal rate (Q/min) 6. Short manufacturing time PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 9

ADVANTAGES OF THE NEW TECHNOLOGY ® ADVANTAGES OF THE NEW TECHNOLOGY This new technology can also be used as a save process to cut super alloys like Inconel or Titanium alloys. Only necessary change: Parameters, NC program, Adopted tools PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 10

ADVANTAGES OF THE NEW TECHNOLOGY ® ADVANTAGES OF THE NEW TECHNOLOGY -With one set of tool for defined geometry, all kinds of notch forms can be machined. -No limitations! -Down- cut or up- cut milling operation for the final tool. -Small distance to the next turbine disc on a rotor will cause no collision trouble due to size of cutting tool PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 11

„STATE OF THE ART TECHNOLOGY“ ® „STATE OF THE ART TECHNOLOGY“ BROACHING TECHNOLOGY Classic technology for serial aerospace turbine disk manufacturing Stationary gas turbines or discs can be manufactured on Multitasking machines (f.ex. WEINGARTNER mpmc). IRUBA`s solution can easily be applied to mill the fir tree slots in all kind of materials PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 12

BASICS OF THE STANDARD TECHNOLOGY ® BASICS OF THE STANDARD TECHNOLOGY Present technologies carry often main disadvantages: No save process (full enlacement / Insert-/tool breakage) Damage on work piece and/or spindle 3. Big amount on special tools 4. High cutting forces 5. Long manufacturing time 6. High total cost of production PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 13

RESULTS OF A REAL TEST WALDRICH COBURG - MULTI TEC PATENTED TECHNOLOGY ® RESULTS OF A REAL TEST WALDRICH COBURG - MULTI TEC PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 14

RESULTS OF A REAL TEST Requirements of the machine: 1. 2. 3. ® RESULTS OF A REAL TEST WALDRICH COBURG - MULTI TEC 1. 2. 3. Requirements of the machine: Dynamic feed of 2 Axis (X-Y) up to 2000 mm/min on small diameter circulation Spindle speed in correlation to diameter of tool max. 5000 Rpm PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 15

RESULTS OF A REAL TEST Material (EU) : 1.2312 ® RESULTS OF A REAL TEST WALDRICH COBURG - MULTI TEC Material (EU) : 1.2312 Length of Notch : 150,00 mm Total Depth of Notch: 98,00 mm 1. Step by Carbide Form End -Mill ae: ~ 2,0 mm ap: 36,0 mm te: ~ 3 min Q: ~ 85 cm³/min 3. Step by Carbide Form End -Mill ae: ~ 1,5 mm ap: 30,0 mm te: ~ 3 min Q: ~ 28 c m³/min 2. Step by Carbide Form End -Mill ae: ~ 1,8 mm ap: 30,0 mm te: ~ 3 min Q: ~ 45 cm³/min PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 16

PROJECT MANAGEMENT „GREEN BUTTON“ TECHNOLOGY CONCEPT OUTLINE TESTS ® PROJECT MANAGEMENT „GREEN BUTTON“ TECHNOLOGY CONCEPT OUTLINE TESTS SCHEDULING IMPLEMENTING PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 17

® THE MISSION PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 18

„GREEN BUTTON“ TECHNOLOGY ® „GREEN BUTTON“ TECHNOLOGY Customer will receive: Complete new designed serial tool concept Complete NC -programming of milling path for each geometry Realistic parameters adjusted for tools, machine and material Clamping -system with required accuracy and clamping -forces as well with special cooling concept (water based / oil / ATS/Co2) PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 19

AEROSPACE INDUSTRY Realistic tests at DPS (DELCAM UK) workshop ® AEROSPACE INDUSTRY Realistic tests at DPS (DELCAM UK) workshop Original material of INCONEL 718 Spindle: HSK63A / HSK100A / NEW!: ATS/ CO2 Coolant supply Advantage: No loss of precious machining time at customers tool shop PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 20

STATIONARY GAS INDUSTRY ® STATIONARY GAS INDUSTRY Realistic Tests on MC up to Diam. 1300 and/or max. 3,0 to. Original Material or similar Spindle: HSK100 Advantage: No loss of precious Machining time at Customers Tool Shop PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 21

SCHEDULING/ IMPLEMENTING ® SCHEDULING/ IMPLEMENTING DEFINITION OF PROJECT COSTS ENGINEERING TO GET MANUFACTURING TIME AND PRICING OF TOOLS CONTRACT - Example at bottom: Slot length:120mm 2 roughing tools, 1 finish tool, Total machining time: 4 min/ slot PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 22

SUMMARIZE OF ADVANTAGES ® SUMMARIZE OF ADVANTAGES According to several different test on big and small machines and due to 5 years of use at the production site at the ABB (CH). Customer will save about 30% machining time, compared to fastest available milling technology Compared to 800mm disk (Mat. Turbine steel) about same production time by milling than broaching Accuracy and surface quality will improve compared to broaching Dramatic increase of machine flexibility, new invest of broaching machine can be saved, deburring and probing on M/C available. PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 23

ADVANTAGES of milling by IRUBA vs. broaching ® ADVANTAGES of milling by IRUBA vs. broaching Job description broaching center vs. 5 axis miil –turn center Setup time per disc /serie 0,5- 1h 5 min max. /Pallet Setup time new serie 6h – 24h 0,5h Lead time for broach /tool Up to 8 month Up to 6 weeks Curved slots Not possible limitless Deburring Both sides in one setup Probing 2. setup/ no measuring Same setup Roughing + finishing Two setup One setup Enviroment Oil Water based/ATS/Co 2 PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 24

ADVANTAGES of milling by IRUBA vs. broaching ® ADVANTAGES of milling by IRUBA vs. broaching Job description broaching center vs. 5 axis miil –turn center Footprint in workshop About 150m2 10 – 50m2 Option drilling Not possible No limit Option turning Power Consumtion Up to 100KW 45 -56KW / max. 50% Flexibility Very limited Very high Investment 2 – 20 Mio € 300Tsd – 4Mio € ROI 3 -5 Years 1,5 Years Cost per hour 150- 350€ 70- 200€ PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 25

THINK ABOUT HOW TO CONVINCE FOR PRODUCTS MADE FOR „GREEN TECHNOLOGY “- ® THINK ABOUT HOW TO CONVINCE FOR PRODUCTS MADE FOR „GREEN TECHNOLOGY “- BY USING ALMOST 100 YEAR OLD HEAVY POWER CONSUMING MACHINETOOL TECHNOLOGY? PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 26

THINK ABOUT FACTS: IRUBA TECHNOLOGY REDUCES MORE THAN 50% POWER ® THINK ABOUT FACTS: IRUBA TECHNOLOGY REDUCES MORE THAN 50% POWER CONSUMTION BY PRODUCTION SAME WORKPIECE LESS MACHINING TIME , LOW LEAD TIME OF TOOLS, HIGHEST FEXIBILITY AT THE PRODUCTION SITE - SMALL „FOOTPRINT“ MACHINES WITH ALMOST DOUBLE PRODUCTIVITY ALL IN ONE -MILLING / TURNING / DRILLING / IRUBA „BROACHING“ / DEBURRING / PROBING ON ONE M/C - NEW: INCONEL FIR TREE MILLING WITH ATS/CO2 COOLANT PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 27

® THANK YOU PATENTED TECHNOLOGY GM: MATTIAS RUTSCHINSKI 28