1. Strategy for minimizing machining distortions
(MIND)

3. ORGANISATION PROFILE
- RISE, Research institutes of Sweden, is Sweden’s research institute and innovation partner. Our 2,700 employees engage in and support all types of innovation processes.
- RISE offers unique expertise and over 100 testbeds and demonstration environments.
- RISE performs applied research together with companies and other research organisations such as universities and institutes

4. PROPOSAL INTRODUCTION (I)
Vision:
Develop and Implement an overall smart strategy for minimizing residual stresses
and process induced distortions in industrial applications like AM.
Motivation: Several high valued machined parts with complex geometric profiles,
material removal processes undergo multistage manufacturing experience distortions
caused by what happened earlier in the value chain. This costs hugely the machining
of parts in aeronautical, auto and locomotive industry.
The project results will improve product quality and increase the competitiveness of
European companies on a global market.
Content:
Based on prior works and results, the project will develop and implement an overall
strategy that include:
Accurate prediction of machining distortions due to initial stresses
Rapid/online part inspection using high precision distortion measurement
Compensation using smart adaptive work-holding systems and rapid toolpath optimization.
AI assisted distortion source identification from inspection data.

5. Post AM machining for elimination of distortions
AM part
Compensate
Toolpath or/and fixture
Estimation and 3D profiling of the residual stresses
need compensation?
Estimation of distortion due to RS during machining
Machining
Optical distortion measurement
Yes No

6. PROPOSAL INTRODUCTION (II)
Expected Outcome:
Improved possibilities to
- Tighten tolerances - Reduce number of scrap components and material waste - Minimize reprocessing - Improve the design of workpiece holding systems - Reduce manufacturing costs
- Realise Automatic postproduction
Impacts:
By taking into account the residual stress release during and after machining a significant improvement in dimensional accuracy will be achieved.
This will save millions of Euros in scrap costs and correction procedures
for the manufacturing industry.
Schedule:
Start: 2020 –
End: – 08 – 31
Duration: 24 Months

7. PARTNERS Current Consortium:
Swe research organisations: RISE IVF, KTH Ind production,
UK research organisations: AFRC
Swe Companies: GF Machining Solutions System 3R,
UK companies: To be decided
Swiss companies: prel. GF Machining Solutions EDM/WEDM
Partner search:
Supply chain with companies including CNC manufacturer
- Swedish companies: …
- UK companies ..
- Swiss Companies ..

8. CONTACT INFO
Contact info:
Mats Werke RISE IVF – PhD Component manufacturing
Tel:
Postal address:
Box 104
SE Moelndal, Sweden