1. WHO IS IRUBA INNOVATIONS?
WHO IS IRUBA INNOVATIONS?
INNOVATIONS & IDEAS
RUTSCHINSKI MATTIAS - Face and CEO
BAUER JOACHIM – Tool head and CEO
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 1

2. WHO IS IRUBA INNOVATIONS?
WHO IS IRUBA INNOVATIONS?
Founded 1. August GbR / GmbH
Tools are only made at the J. Bauer GmbH
Specials are our specialty (accuracy / design/ form)
IRUBA offers solutions
2012 start of strong collaboration with DPS
(Delcam professional services UK)
several new Partner to complete solutions
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 2

3. INNOVATIVE GREEN TECHNOLOGY
INNOVATIVE GREEN TECHNOLOGY
MANUFACTURING OF
FIR-TREE-ROOT NOTCHES
GERMAN ENGINEERING / PATENT
TOOLS MADE IN GERMANY
CARBIDE MADE IN GERMANY
GERMAN SUPPORT WORLDWIDE
REMANUFACTURING OF TOOL IN GERMANY
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 3

4. NEW WAYS BETTER SOLUTIONS INNOVATIONS NEW TECHNOLOGIES
NEW WAYS
BETTER SOLUTIONS
INNOVATIONS
NEW TECHNOLOGIES
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 4

5. THE IDEA FOR THE NEW TECHNOLOGY
THE IDEA FOR THE NEW TECHNOLOGY 1. 2. 3.
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 5

6. BASICS OF THE NEW TECHNOLOGY
BASICS OF THE NEW TECHNOLOGY
A ROUGHING OPERATION
- WITH HIGH THERMAL DEVELOPMENT
- BIG CUTTING FORCES
- LOW CHIP-REMOVAL-RATES
WILL CHANGE INTO A „FINISH OPERATION“
- WITH LOWEST THERMAL DEVELOPMENT
- LOW CUTTING FORCES
- HIGH CHIP REMOVAL RATES
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 6

7. BASICS OF THE NEW TECHNOLOGY
BASICS OF THE NEW TECHNOLOGY
Special carbide end mill
Low cutting forces, almost no thermal development on the cutting edge
Interpolating
high performance cutting with
only “3“ levels
Open the slot -and put in the undercut geometry, will be performed in one single step
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 7

8. FIR -TREE -ROOT NOTCHES
BASICS OF THE NEW TECHNOLOGY
Interpolating
by HPC to manufacture notches on a rotor
Straight notches,
Ankle notches,
Radius notches,
Always
rough-milling without full
enlacement
END -MILL
FIR -TREE -ROOT NOTCHES
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 8

9. BASICS OF THE NEW TECHNOLOGY
BASICS OF THE NEW TECHNOLOGY
Advantages:
1. Highest process safety
2. No thermal contribution into
boundary layer of work piece
3. Lowest cutting forces (low KW
4. Low amount of carbide special
tools
5. High chip removal rate (Q/min)
6. Short manufacturing time
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 9

10. ADVANTAGES OF THE NEW TECHNOLOGY
ADVANTAGES OF THE NEW TECHNOLOGY
This new technology can also be used as a save process to cut super alloys like Inconel or Titanium alloys.
Only necessary change:
Parameters, NC program, Adopted tools
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 10

11. ADVANTAGES OF THE NEW TECHNOLOGY
ADVANTAGES OF THE NEW TECHNOLOGY
-With one set of tool for defined geometry, all kinds of notch forms can be machined.
-No limitations!
-Down- cut or up- cut milling operation for the final tool.
-Small distance to the next turbine disc on a rotor will cause no collision trouble due to size of cutting tool
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 11

12. „STATE OF THE ART TECHNOLOGY“
„STATE OF THE ART TECHNOLOGY“
BROACHING TECHNOLOGY
Classic technology for serial aerospace turbine disk manufacturing
Stationary gas turbines or discs can be manufactured on Multitasking machines (f.ex. WEINGARTNER mpmc).
IRUBA`s solution can easily be applied to
mill the fir tree slots in all kind of materials
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 12

13. BASICS OF THE STANDARD TECHNOLOGY
BASICS OF THE STANDARD TECHNOLOGY
Present technologies carry often main disadvantages:
No save process (full enlacement / Insert-/tool breakage)
Damage on work piece and/or spindle
3. Big amount on special tools
4. High cutting forces
5. Long manufacturing time
6. High total cost of production
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 13

14. RESULTS OF A REAL TEST WALDRICH COBURG - MULTI TEC PATENTED TECHNOLOGY
RESULTS OF A REAL TEST
WALDRICH COBURG - MULTI TEC
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 14

15. RESULTS OF A REAL TEST Requirements of the machine: 1. 2. 3.
RESULTS OF A REAL TEST
WALDRICH COBURG - MULTI TEC 1. 2. 3.
Requirements of the
machine:
Dynamic feed of 2 Axis (X-Y) up to 2000 mm/min on small diameter circulation
Spindle speed in correlation to diameter of tool max Rpm
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 15

16. RESULTS OF A REAL TEST Material (EU) : 1.2312
RESULTS OF A REAL TEST
WALDRICH COBURG - MULTI TEC
Material (EU) :
Length of Notch : 150,00 mm
Total Depth of Notch: 98,00 mm
1. Step by Carbide Form End -Mill
ae: ~ 2,0 mm
ap: 36,0 mm
te: ~ 3 min
Q: ~ 85 cm³/min
3. Step by Carbide Form End -Mill
ae: ~ 1,5 mm
ap: 30,0 mm
te: ~ 3 min
Q: ~ 28 c m³/min
2. Step by Carbide Form End -Mill
ae: ~ 1,8 mm
ap: 30,0 mm
te: ~ 3 min
Q: ~ 45 cm³/min
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 16

17. PROJECT MANAGEMENT „GREEN BUTTON“ TECHNOLOGY CONCEPT OUTLINE TESTS
PROJECT MANAGEMENT
„GREEN BUTTON“ TECHNOLOGY CONCEPT
OUTLINE
TESTS
SCHEDULING
IMPLEMENTING
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 17

18. THE MISSION
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 18

19. „GREEN BUTTON“ TECHNOLOGY
„GREEN BUTTON“ TECHNOLOGY
Customer will receive:
Complete new designed serial tool concept
Complete NC -programming of milling path for each geometry
Realistic parameters adjusted for tools, machine and material
Clamping -system with required accuracy and clamping -forces
as well with special cooling concept (water based / oil / ATS/Co2)
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 19

20. AEROSPACE INDUSTRY Realistic tests at DPS (DELCAM UK) workshop
AEROSPACE INDUSTRY
Realistic tests at DPS (DELCAM UK) workshop
Original material of INCONEL 718
Spindle: HSK63A / HSK100A / NEW!: ATS/ CO2 Coolant supply
Advantage:
No loss of precious machining time at customers tool shop
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 20

21. STATIONARY GAS INDUSTRY
STATIONARY GAS INDUSTRY
Realistic Tests on MC up to Diam and/or max. 3,0 to.
Original Material or similar
Spindle: HSK100
Advantage:
No loss of precious Machining time at Customers Tool Shop
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 21

22. SCHEDULING/ IMPLEMENTING
SCHEDULING/ IMPLEMENTING
DEFINITION OF PROJECT COSTS
ENGINEERING TO GET MANUFACTURING TIME
AND PRICING OF TOOLS
CONTRACT
- Example at bottom: Slot length:120mm 2 roughing tools, 1 finish tool,
Total machining time: 4 min/ slot
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 22

23. SUMMARIZE OF ADVANTAGES
SUMMARIZE OF ADVANTAGES
According to several different test on big and small machines and due to 5 years of use at the production site at the ABB (CH).
Customer will save about 30% machining time, compared to fastest
available milling technology
Compared to 800mm disk (Mat. Turbine steel) about same
production time by milling than broaching
Accuracy and surface quality will improve compared to broaching
Dramatic increase of machine flexibility, new invest of broaching machine can be saved, deburring and probing on M/C available.
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 23

24. ADVANTAGES of milling by IRUBA vs. broaching
ADVANTAGES of milling by IRUBA vs. broaching
Job description broaching center vs axis miil –turn center
Setup time per disc /serie
0,5- 1h
5 min max. /Pallet
Setup time new serie
6h – 24h
0,5h
Lead time for broach /tool
Up to 8 month
Up to 6 weeks
Curved slots
Not possible
limitless
Deburring
Both sides in one setup
Probing
2. setup/ no measuring
Same setup
Roughing + finishing
Two setup
One setup
Enviroment
Oil
Water based/ATS/Co 2
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 24

25. ADVANTAGES of milling by IRUBA vs. broaching
ADVANTAGES of milling by IRUBA vs. broaching
Job description broaching center vs axis miil –turn center
Footprint in workshop
About 150m2
10 – 50m2
Option drilling
Not possible
No limit
Option turning
Power Consumtion
Up to 100KW
45 -56KW / max. 50%
Flexibility
Very limited
Very high
Investment
2 – 20 Mio €
300Tsd – 4Mio €
ROI
3 -5 Years
1,5 Years
Cost per hour € €
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 25

26. THINK ABOUT HOW TO CONVINCE FOR PRODUCTS MADE FOR „GREEN TECHNOLOGY “-
THINK ABOUT
HOW TO CONVINCE FOR PRODUCTS MADE FOR „GREEN TECHNOLOGY “-
BY USING ALMOST 100 YEAR OLD HEAVY POWER
CONSUMING MACHINETOOL TECHNOLOGY?
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 26

27. THINK ABOUT FACTS: IRUBA TECHNOLOGY REDUCES MORE THAN 50% POWER
THINK ABOUT
FACTS:
IRUBA TECHNOLOGY REDUCES MORE THAN 50% POWER
CONSUMTION BY PRODUCTION SAME WORKPIECE
LESS MACHINING TIME , LOW LEAD TIME OF TOOLS,
HIGHEST FEXIBILITY AT THE PRODUCTION SITE
- SMALL „FOOTPRINT“ MACHINES WITH ALMOST DOUBLE
PRODUCTIVITY
ALL IN ONE -MILLING / TURNING / DRILLING / IRUBA „BROACHING“ /
DEBURRING / PROBING ON ONE M/C
- NEW: INCONEL FIR TREE MILLING WITH ATS/CO2 COOLANT
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 27

28. THANK YOU
PATENTED TECHNOLOGY
GM: MATTIAS RUTSCHINSKI 28