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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 2 - TGRIP (Nanostructured gripping material for clamping complex workpieces)

Teaser

Summary

\"\"\"Complex high-value pieces are a growing field, particularly in high requirement sectors like the aeronautic, and especially in Europe, where 30-40% of worldwide manufacturing of these pieces is concentrated. Remarkable examples of these pieces are fuselage structures and complex pieces of the jet engines (large pieces with complex geometries, requiring (up today) several consecutive clamping-machining operations and several workholding fixtures).
Actual clamping systems (mechanical, vacuum and electromagnetic) for these pieces are complex systems with some fixture-piece clamping elements which create the required union forces. Main clamping systems used in the industry are not fulfilling markets demands as the machinability is complex, quatility of the machining is not as good as expected and the overall cost (tooling and machining) are high.
FRESMAK, in collaboration with POLYMAT (University of Basque Country), has developed an alternative innovative clamping solution, called TGRIP, based on the principle of reversible adhesion. The developed adhesive is a nanostructured bi-phase polymer with different adherence phases which is controlled with the temperature. Temperature governance allows to stick and unstick any kind of materials with a high clamping force (1100N/cm2) and without compromising cutting areas. This condition made this adhesive excellent for clamping the work-piece and a fixture.
The TGRIP solution is formed by the adhesive material and the complete clamping fixture with temperature driven adhesion activation system
The overall objective of this project is the LAUNCH OF TGRIP BUSINESS through the INTRODUCTION OF TGRIP IN THE MAIN GLOBAL REFERENCE MARKETS OF INDUSTRIAL SUBCONTRACTORS OF HIGH VALUED MANUFACTURING INDUSTRIES and SCALING UP MANUFACTURING AND BUSINESS STRUCTURE.
As a part of the commercialisation plan to introduce and commercialise TGRIP worldwide, this project aims to introduce TGRIP in European Aeronautic Industry which will boost the introduction in the rest of the markets in a second stage of commercialisation after this project.\"\" \"

Work performed

Product:
The 1st F-GRIP machining tests have been carried on internally. Due to unexpected failures, an investigation campaign led us to modify the concept of the F-GRIP fixtures. After the internal validation of prototypes, the new concept have been applied to the 1st demonstrator tooling. The 1st test has been performed and analyzed. It is now under adjustment to improve the performance.
In parallel of the 1st demonstrator, technical studies are running with the other partners of the projects (design and adhesion tests). Each case is specific as it depends on various parameters: part design, material, force requirement, other specifications...) which makes each demo study very intense in terms of analysis of the part.
On the other hand, investigations are carried out about the formulation of the F-GRIP adhesive. Even if no concrete result is available now, the 1st attempts are promising.

Manufacturing:
During the 2nd period, the cell prototype has been put into operation. The production scale-up study is ongoing to be prepared to produce in industrial quantity. For this, each of the influent parameters of the adhesive fabrication process are under analysis.
The resulted needs in terms of equipment will be considered during the study of FRESMAK scaling-up in the 3rd period

Promotion:
As planned, Fresmak presented the F-GRIP in 5 different fairs (in a booth or as visitor). 2 of these fairs were dedicated to the aerospace sector. As a result of the action, more than 60 new relevant companies could know about the F-GRIP and especially 5 are now in close contact to perform tests or feasibility studies.
The on-line coomunication has been affected by the lack of publishable information from the demonstrator activities (only internal). Nevertheless, the social networks are still in activity and the website has been updated to make it more dynamic.

Final results

\"\"\"The main advantage offered by TGRIP over these technologies is the combination of high clamping force, low interference with cutting tool and low cost. TGRIP does not require complex auxiliary components in order to create the clamping forces: just to put the disk and heat it up.
TGRIP is suitable for the metal cutting industry operating in the manufacturing of high complexity pieces. Some relevant industries that could benefit from TGRIP technology are metal cutting industries involved in the manufacturing pieces for:
â€¢ Aerospace industry
â€¢ Power and Oil&Gas industries: valves, gas turbine blades, rotors.
â€¢ Mold&die industry
â€¢ Infrastructures and civil engineering: valves, gates for damsâ€¦
â€¢ Heavy industries: cement, iron and steel, ship-buildingâ€¦
The main current market for TGRIP is the collective of industrial subcontractors, particularly Tier2 and Tier3 companies, in the European aerospace supply chain.
The main economic benefits for the users, in comparison between TGRIP based solution and current solution (mechanical) for this real representative case studied in the made tests, are as follows:
â€¢ Fixture cost reduction (up to 70%):
Less machining operations allows using 1 fixture instead of multiple (3 in this case
Individual fixtures price reduction (20%) due to the removal of clamping components of the fixture.
â€¢ Machining costs reduction (labour hand and machine using cost) up to 30%. machining time reduction is directly related with cost reductions (up to 30%)

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