MIDEMMA

Minimizing Defects in Micro-Manufacturing Applications

 Partecipanti

Mappa

 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

 Obiettivo del progetto (Objective)

'Micro-manufacturing requires 'Zero-Defect' oriented approaches, both in large scale and in short-run production. Current quality control approaches, coming from macro-manufactring, are mainly based on post-process geometric control, which produces a large time lag between the defect generation and its detection, usually leading to large amount of defect parts (large scale) or wasted high value processing (short run). Moreover, this approach does not immediately point the error source to help with error correction, and other criteria such as material integrity, physical properties, surface topography and piece or component functionality are not taken into account typically. There is clear need for extending the final product validation to a process monitoring approach in micro-manufacturing, where all the manufacturing process is monitored, from the raw material to the fabrication processes and the manipulation of the final parts, and where all this information is processed in real time with suitable models for error prediction, automatic detection and process optimization by system correction. The project will give a global solution for the 'zero defect' approach in micro-manufacturing, with a focus on the aspects that are specific to micro-manufacturing. The develop technologies concepts are expected to have in impact in the competitiveness of the micro-manufacturers in the following ways: - reducing process variability detecting defects as soon as they are generated or in the case that it is possible, are going to be generated by predicting models. - allowing the use of less expensive machines, that can reduce their variability through monitoring. - requiring less skilled working force, thanks to acquired process setting knowledge and the development of smart decision-making tools.'

Introduzione (Teaser)

Zero-defect manufacturing that reduces waste, time and cost is the ultimate goal of industry. Process monitoring and adaptive control promise a step-change in competitiveness compared to conventional final product inspection.

Descrizione progetto (Article)

Small and medium-sized parts with geometrical requirements in the micro- or nano-metre range have huge markets in fields such as micro-engineering, medical and optical devices.

However, quality control for such micro-manufacturing is lacking.

EU-funded scientists working on the project 'Minimizing defects in micro-manufacturing applications' (http://www.midemma.eu/ (MIDEMMA)) are extending final product validation to include raw material, workpiece and process monitoring and optimisation.Technologies will decrease process variability and enhance product quality.

Less expensive machines can then be used with better monitoring and optimisation.

This will also reduce knowledge requirements of operators through the integration of smart decision-making tools.Partners have demonstrated excellent progress in developing on-machine devices for workpiece characterisation and manipulation.

One new workpiece fixture boasts smart technology to monitor and adapt to workpiece deformation and displacement.

An ultra-precision manipulating system will deliver excellent positional accuracy and repeatability during micro-machining operations.

Researchers have also developed an on-machine microscope to measure manufactured features on the micron and sub-micron scales.Process monitoring technologies are targeted at micro-machining and micro electro-discharge machining (EDM, a non-contact technique), ultra-fast laser ablation and micro-injection (plastic injection moulding).

Numerous advances were realised in the first 18 months.

This includes capabilities for online measurement of micro-machining tool shape, sparking pulse characteristics, laser pulse energy, and injection moulding process temperature and pressure parameters.Adaptive process control utilises the data from process monitoring to automatically set up process parameters, detect errors and adapt operating conditions.

Partners have begun to assess the generation of tool wear during micro-machining and micro-EDM as well as the use of sensors, compensation mechanisms and control strategies.Simultaneously, scientists have defined requirements of Proactive Data Management Tools for each of the targeted processes.

Analysis of monitoring data is being used to develop the requisite predictive models that will assist operators in making strategic process decisions.MIDEMMA technologies promise a step-change in the way the EU's micro-manufacturers do business.

Important advances in quality will benefit the numerous end users in the fields of micro-engineering components and ultra-precision optics and lenses.