OUR INSPIRATION AT R&D

Research and development has traditionally been a key priority at FOOKE. Innovations that enable us to outstand our competitors form the core of our work.

Your partner for complex high-end products

Research and Development at Fooke

We develop complex, high-end products, globally regarded as technology drivers in the machine tool sector. Our decades of experience in machine-tool-related research and development enable us to offer competitive advantages to our customers worldwide. We aim to use our development activities to further increase our products’ added value for our customers.

It has been and will always be the goal of our research and development to design our products in a forward-looking and resource-saving way. In particular, we will continue to set standards in the energy efficiency of machine tools. The quality of motion control and the interaction of the tool and the workpiece at the tool center point are always the primary focus of our research and development activities.

 

A machine structure optimally designed by means of FEM as well as the integration of high-performance machine elements, such as non-contact linear motors, ensure excellent quality of motion control and a particularly stable and dynamic process.

Special requirements and processes demand special solutions.

In close cooperation with our customers, we develop product- and process-specific machines and systems. After a detailed analysis of your machining task, we propose technical and economic solution concepts and show alternatives.

 

The design of all machine elements and the holistic simulation ensure the achievement of these target values. Our many years of experience and our special know-how are the basis for the theoretical representation of reality. Therefore, we can reliably determine the performance and productivity of a system in advance.

 

Linear motor technology

Technology at the cutting edge

The use of linear motor technology guarantees design and mechanical advantages.
Since 2004, FOOKE GmbH has been systematically and successfully using linear motors in its ENDURA product range.

Compared to conventional drives such as ball screws or pinion-racks, a machine tool equipped with linear motor technology is characterized by high drive rigidity, which is the result of the reduction of transmission elements in the drive. The force flow from the motor to the mechanics on the output side takes the shortest path, so that backlash, elasticities and friction, which are responsible for limiting the dynamics, are eliminated. In addition, fewer mechanical disturbances are transmitted to the machine tool. 

 

High machine dynamics with best surface quality

The aforementioned mechanical-geometrical properties of the linear motor in combination with its high drive stiffness result in a significantly higher position control gain KV compared to conventional drives. Consequently, higher feed rates can be realized while maintaining a specified lag distance, which is usually <1 µm. In coordination with the structure natural frequencies, individually optimal dynamic parameter sets (jerk, acceleration) are tuned to keep the overshoot as small as possible.

Consequently, excellent surfaces and very high positioning accuracies can be achieved in minimum time with the help of linear motor technology.

 

Linear motor, the more economical drive?

The contactless and wear-free drive ensures a long service life, so that the costs for assembly and service work remain low. This is also evident in the event of a collision. Whereas with conventional drives, distortions or damage to the drive can quickly occur, resulting in high costs and time expenditure, the linear motor is unaffected.

The linear motor also has economic advantages in terms of running operating costs. Empirical studies show that the total energy consumption per workpiece is lower with linear-driven machine tools, due to the shorter machining time.

 

Highlights and advantages of linear motor technology

  • High axis dynamics (jerk, acceleration, speed)
  • Low position error
  • High KV factor
  • High contour, positioning and repeat accuracy
  • Wear-free and drive rigid
  • Excellent contour accuracy
  • Energy efficient

 

  • Highly dynamic (highly adjustable jerk and acceleration)
  • Drive rigid
  • Few mechanical transmission elements
  • Less interference on the machine structure
  • No backlash during reversal movement
  • High Kv factor possible
  • Excellent surface quality and positioning accuracy
  • Easy to assemble, maintain and service
  • Energy efficient
  • Wear and friction free

 

Increase your productivity

with the innovative FOOKE performance kits!

FOOKE Dynamic Damping

INCREASE YOUR PRODUCTIVITY BY UO TO 300%

Increase your productivity in the machining of high-strength materials by up to 300%. FOOKE Dynamic Damping increases the stability of your machine tool, preventing process-limiting chatter while providing the highest quality surfaces.
Specially developed actuators matched to the gantry milling machine generate counter-phase vibrations that actively and intelligently stabilize the overall machine system.

 

YOUR ADVANTAGES
- Increased metal removal rate by up to 300%.
- Improved surface quality requires less rework.
- Increased tool life by up to 30%.
- Increased spindle life due to reduced loads.
- Expand the range of applications for your portal milling machine from easy-to-machine non-ferrous metals to tough-to-machine high-alloy steels.

BENEFIT NOW
- Easy operation and handling.
- Can be switched on and off at any time.
- Also available as a retrofit solution for existing milling machines.

 

FOOKE Machine Monitoring

SAFETY FOR MACHINE AND COMPONENT

Save unnecessary costs with FOOKE Machine Monitoring by avoiding tool breakage and structural component overload. With our Machine Monitoring you ensure the optimal production parameters during machine operation. An integrated acceleration sensor near the milling point analyzes the vibrations occurring during the milling process and visualizes them on the control system. Process- and machine-specific vibration limits are defined to prevent a hard crash and protect the tool, machine and component. The consequences are a significant reduction in machine and tool damage as well as unplanned machine downtime.

YOUR ADVANTAGES
- Reduction of unplanned machine downtime.
- Analysis of the milling processes during operation.
- Quick intervention through process visualization.
- Reduction of tool breakage by 90%.
- Collision detection up to machine stop.
- Low component damage.

BENEFIT NOW
- Simple operation and handling.
- Can be switched on and off at any time.
- Also available as a retrofit solution for existing milling machines.

 

FOOKE Thermo Guard

INCREASING TEMPERATURE STABILITY FOR HIGHER ACCURACIES

FOOKE Thermo Guard protects the structural parts of your machine such as the Z-axis, gantry and side walls from external
temperature influences: The machine insulation protects against rapid temperature changes (open hall door, solar radiation) and keeps the structural temperature at a stable level. Consequently, misalignments at the Tool Center Point (TCP) are reduced, which leads to a significant increase in positional and repeat accuracy and reduces rework on the workpiece.

 

YOUR ADVANTAGES
- Increased accuracies by up to 75%.
- Increased positional and repeatability accuracy.
- Reduction of rework on the workpiece.

BENEFIT NOW
- Also available as a retrofit solution for our 700 series.
- Stabilization of the machine structure against external, short-term temperature changes.

We are driven by the passion for technology.
Our innovative R&D – Projects.

HYBRIDi

Development of an intelligent lightweight structure for hybrid machine tools

In a joint R&D project, the development of an intelligent lightweight component as an integral part of an ENDURA® 700LINEAR machine tool from FOOKE GmbH was carried out together with well-known project partners. Due to its central function within the machine tool, the vertical Z-slide was selected as a demonstrator component. The material of the conventional cast Z-slide was substituted by a hybrid mixed design of fiber composite plastics and metallic materials. At the same time, research was conducted into the installation of sensor networks, which are easy to implement and integrate, in composite structures for permanent monitoring of process behavior.

The major potential of structural elements of fiber composite plastics was successfully demonstrated in extensive metrological investigations.

 

Advantages:

Productivity: + 15 %                      

Accuracy: + 70 %

Energy expenses: - 20 %

Improvement of surface quality by BMBF

This project was sponsored

Youtube: youtu.be/bvU-66U7V2U

 

HyLaB

Machine concept for Hybrid Laser Machining in Contour Milling of Large  Fiber Composite Structures (Laser-Scored-Machining)

In a joint R&D project, a new concept for the machining of large fiber composite structures was developed together with renowned project partners. In this process, a laser beam is guided along the component edge in the lead-up to the milling cutter. The combination of lasers and milling combines the advantages of both manufacturing processes and ensures a high-quality component edge that requires no further reworking.

The applicability of the process has been demonstrated for various fiber-reinforced composites - in particular also for demanding CFRP laminates with unidirectional face sheets or also GFRP or Coppermesh face sheets, which are frequently used in the aerospace industry (segment CFRP wing shell A320).

 

Advantages:

Productivity: + 30 %

Tool life: + 40 %

Increase in componet edge quality -> no rework.

This project was sponsored by BMWi

Youtube: youtu.be/xaEtiFBRSWk

 

CFRP Tool

Development of a CFRP Base Body for Metal-cutting Machining

Together with the IFW of the University of Hanover and Invent GmbH, a large milling cutter made of fiber-reinforced plastics and aluminum honeycomb was developed which is suitable for the production of aluminum precision plates. It was possible to reduce the mass by 80%, which significantly improved the dynamic system-defining properties.

The large milling cutter that has been developed has already been used by a well-known customer over a period of more than 18 months. The theoretically determined advantages could be confirmed in real production operation.

 

Advantages:

Surface quality: + 50 %

Mass reduction: - 80 %

Improved inlet and outlet behavior.

This project was sponsored by BMBF.

 

Green

Energy-efficient Machine Tool through Innovative Cooling System

Together with the IFW of the University of Hannover, an exemplary machine tool of FOOKE GmbH of the type ENDURA® 900LINEAR was equipped with an active cooling concept in order to compensate for displacements of the TCP due to temperature deviations. For this purpose, the sensitivity of individual structural elements was described in relation to different applied heat rates and equalized by the active cooling.

The active cooling concept guarantees the smallest possible deviations at the TCP for machine tools. Especially in production halls, where the temperature deviates by more than 5°C during the day, this system offers the solution.

 

Advantages:

Accuracies: + 45 %

Reduced measurement times

Less component scrap.

This project was spoonsored by BMWi.

 

AMAvia

Digitized process chain for the innovative combination of laser light-arc hybrid additive manufacturing (LLHAM) and intelligent milling processes to increase productivity and quality in the manufacture of large metallic structures in the aviation industry

Project time line: 11-01-2020 / 10-31-2024

Project partners: Ceratizit - Fraunhofer IAPT - Heggemann AG - IPMT TU Hamburg - Racontec - Siemens AG

 

Core Content:

Cost-efficient and resource-efficient manufacturing of aluminum and titanium structural components for the aerospace industry.

Increasing build-up rates in additive manufacturing through laser-based welding

Development of an adaptive milling strategy to compensate for component distortions caused by the release of residual stresses