COPTER - Metrología aplicable a geometrías de alta complejidad para transmisiones de ultraprecisión

Objective:

The COPTER project is presented as a radical solution to the design, manufacture and inspection of components formed by free-form surfaces; more specifically ultra-precision transmissions. The aim of COPTER is to provide a technological advance in each and every one of the three key stages in the manufacture of components of great geometric complexity and ultra-precision transmissions that are present in aeronautical engines and high vacuum turbines. This project focuses on the comprehensive research of kinematic modelling technologies for ultra-precision transmissions, on the fundamentals of free surface machining processes in multi-axis machines, to configure a platform that allows machine manufacturers to access the market for large special ultra-precision transmissions in very short or unitary series, and users to resolve the manufacture of this type of surface in a competitive manner and with excellent quality and reliability ratios. In addition, COPTER is focused on solving the machining of integrated components in monolithic parts, in small or single series, where the use of general-purpose tools and multi-axis machines makes more sense. Based on this previous motivation, the COPTER project proposes the following scientific-technological objectives that will reinforce the knowledge in the area, the international strategic positioning of the consortium (UPV/EHU, BCAM and Innovalia Association) in the areas of design, manufacturing and production control systems and the future development of technology-based products with a high degree of impact on high-growth industrial sectors: - Technological Objective 1. To generate a leap in the fundamental knowledge of the kinematics of ultra-precision transmissions and free-form surfaces and their geometric modelling, in order to determine the mathematical models of the surfaces to be machined. - Technological Objective 2. Define the most effective machining parameters and strategies for milling highly complex surfaces with general-purpose tools on milling machines or multi-axis machining centres that allow highly complex relative kinematic displacements between the tool and the part. - Technological Objective 3. Development of scanning and optical analysis and inspection techniques, as well as the modelling of the necessary trajectories to close the cycle of a robust design, manufacturing and inspection process and guarantee the strict dimensional requirements of this type of component in a productive manner.