University of Mondragon (MOND)
MGEP is a co-operative integrated into both MONDRAGON Corporation and Mondragon Unibertsitatea (the University of Mondragon) and is the legal owner of Mondragon Unibertsitatea's Faculty Of Engineering.
Its principal activities are training and research, development and innovation.
The team involved in this project is the High Performance Machining Research Group.
The main goals of the High Performance Machining research group are to improve machining processes employed in different industrial sectors (transport, aeronautics, health, machine-tool, moulds and dyes…) and to generate new ideas to manufacture innovative products that will enable entry into new markets or even lead to the launch of new companies.
The research topics are the following one:
High speed cutting is used in sectors as diverse as aerospace or moulds and dyes. Currently, research is carried out in the optimization of the high speed cutting of (I) free form surfaces of hardened steels for its application in the production of moulds and dyes and in (II) titanium machining for its application in the aeronautic sector.
Miniaturization is nowadays a global trend which affects a manufacturing process in several production markets as TICs, electronics or biomedicines. This size reduction implies some process changes, making it more difficult and less reliable.
A micromachining laboratory has recently been set up in order to improve knowledge of micromachining, hence its performance.
Grinding is a finishing process used to obtain parts with a good surface finish and close geometric and dimensional tolerances, which can be badly affected by the presence of chatter and other instabilities. In recent years, new simulation techniques have been developed to determine instability-free configurations, making it possible to guarantee that the final workpiece profile is round. With this information and taking into account other process restrictions, like system static stiffness and workpiece tolerance, the optimal grinding cycle can be designed.
- Chip formation Study and modelling:
The knowledge of the influence that cutting parameters have on different thermomechanical variables (temperature, stresses, strains, etc.) during the chip forming process, is the basis for optimising any machining operation. The combination of experimental tests together with analytical and numerical modelling (Finite Element Modelling-FEM) allows better understanding of the material removal process, facilitating the selection of cutting conditions, tool geometries or even the development of new cutting tool and workpiece materials.
Machinability refers to the ease with which a part or material can be machined. The factors that typically improve a material's performance often degrade its machinability. Therefore, it is very important to find ways to improve machinability without harming performance.
Nowadays we are working on the study of this property with the most advanced experimental techniques in different materials: steels, titanium alloys… The aim of this study is to find the reason that justifies the behaviour of the material during the machining process.
- Knowledge Base Engineering (KBE):
The objectives of KBE or CAX software customization are: firstly, to increase the productivity of CAX software users; secondly, to capture and keep the Product Life Cycle Knowledge as a company asset; and finally / thirdly, to speed up the integration of new employees by giving them access to company’s Product Life Cycle Knowledge as required in a reusable format.
Workshop: Micromilling machine Kern Evo (50.000 rpm/160.000 rpm), High Speed Milling machines LAGUN (18.000 rpm) and Kondia (24.000 r.p.m), CNC Lathes C.N.C., Grinding machine GER, Conventional machine tools
Equipment to study the chip formation process: Force sensors ( turning, drilling, milling, micromilling), IR camera Titanium 550M, High Speed Filming Camera Photron FASTCAM-APXRS, Accelerometers (Vibrations, Acoustic Emission)
Software: Unigraphics, Abaqus, AdvantEdge, Deform
Metrology: MMC, Rugosimeter, Confocal perfilometer
Optical Microscopy: Scanning Electronic Microscope and Microanalysis.
Mechanical Characterisation: Static tests between -80 and +220ºC, micro hardness, instrumented pendulum, behaviour at high strains, tribometer.
Role in the MMTech Project
Experimental tests in order to search for process windows parameters, mainly cutting tools (geometry, coatings) and coolants, ensuring the surface integrity of the componentes and reasonable tool life value
Transformation from orthogonal cutting to oblique cutting to obtain models of cutting foces in comples milling cutting tools