IsoForm - The New Isolated Tool Concept

Transcription

1

2 Fascination Mould Design a new concept for a good future in mould design. IsoForm - The New Isolated Tool Concept for thermoplastic elastomers, thermosets, elastomers and diecasting Fig. 2 Fig. 1 Fig. 3 What are the potentials for product developers, mould designers and injection moulders in order to improve their position on the market? The end-customer is looking for a low-cost injection moulded part that is both technically and visually perfect. Choosing the cheapest offer for the tool not taking into account follow-up costs is no sustainable perspective when the overall costs are considered on a long-term basis. As a result of this short-sighted course of action a considerable demand for tool replacements becomes apparent as saving costs when developing the tool does not pay off! The financial damage for the company as well as for the entire economy is substantial. A holistic approach is urgently needed here! The new isolated tool concept IsoForm forms the basis for a holistic approach including the subsequent advantages for efficiency with regard to costs, time, quality and energy requirements. Konstruktionsbüro Hein GmbH developed the concept and the corresponding standard elements are distributed by the project partner Nonnenmann GmbH. Additional co-operation partners that are currently contributing to the implementation of the concept include BARLOG plastics GmbH, Durotherm Maschinen und Anlagen Vertriebs GmbH, Günther Heisskanaltechnik GmbH, Ingenieurbüro Friedhelm Begemann, Kunststoff Fröhlich GmbH, NovoPlan GmbH, Single Temperiertechnik GmbH, Stemke Kunststofftechnik GmbH, STM Stahl- Vertriebs-GmbH and Teegen Werkzeugbau. As the concept is open for any application we are happy to welcome additional companies to join the innovative circle.

3 Record project costs on a long-term basis (here: plastic injection moulding) Long-term recording of the entire project costs frequently discovers a considerable potential for savings. In order to save inevitable follow-up costs (see fig. 4) it can thus become necessary to invest a little more cost and time into product development always depending on the kind of task. Comparing project costs Fig. 4 Efficiency starts with product development (here: plastic injection moulding) The required consistent and qualified approach already begins with the product development of the plastic part by including an application-oriented injection moulding simulation that takes into account the projected temperature regulation of the tool (fig. 5) and contains a demonstration of distortions. Subsequently, the design is optimised on the basis of the simulation results and, if necessary, of the additional FEM analysis. This approach ensures the best possible result regarding the geometry of the part. A first tool concept including separations of the part and the resulting draft angles is compiled at an early stage. Now, the part design can be finalised with mean tolerances. Thus, the design dataset can remain the same until the final inspection of the manufactured part. Using the result from a second simulation, maybe even that of a simulated negative correction, or including a determined allowance for components reinforced with glass fibres, the tool design can be started. At this point, all parameters regarding feeding, temperature regulation and separations are already available and you can proceed very quickly. Fig. 5 We recommend the approach described above for the implementation of the tool concept in order to be able to use all the advantages the IsoForm concept has to offer. Konstruktionsbüro Hein GmbH provides these services separately or as a complete service.

4 IsoForm the individual program for standard elements The individual concept for standard elements is distributed by the project partner Nonnenmann GmbH. In order to define the necessary standard element an internet tool has been developed which allows the design engineer to predefine the standard element. Questions and their corresponding answers regarding number of cavities, required materials, part size etc. form the basis for the standard element which is then compiled and displayed by the tool. The user can then verify the dimensioning and modify it, if required, e. g. in order to include more space for a slide. Subsequently, the file can be uploaded to the user s CAD system where the geometry automatically establishes itself using control keys and including your CAD system s history. Konstruktionsbüro Hein is your qualified service provider for special solutions and consultant for all IsoForm applications. Isolated mould inserts open up new opportunities for temperature regulation Up to now, the temperature of the entire tool was regulated in order that a consistent temperature level of the entire tool could be obtained. The protected tool concept IsoForm by Konstruktionsbüro Hein only regulates the temperature of the mould inserts and of other components forming the contour of the tool which are isolated from the surrounding tool. Any temperature regulation from conventional up to cycle-dependent methods can be conveniently and individually used here. Fig. 7 Fig. 6 The mould inserts are circumferentially isolated using air and centred using key and slot joints (arrow, fig. 6) made from steel or ceramics. The insert s multi-plate (arrow, fig. 7) below the insert is isolated and serves for supplying the temperature regulation medium as well as for the support of pins and cores. The mould inserts as well as the mould support are isolated from the surrounding tool by means of a high-strength thermal insulation plate. IsoForm tools can be compiled most diversely. For example, standard elements with only one insert are available as well as those with slide(s) or an integrated hotrunner (fig. 8 and fig. 9). Fig. 8 Fig. 9

5 Initiate the process considerably faster while needing a lot less energy The application shown here not only demonstrates that the process temperature is reached at only a fraction of the energy needed without IsoForm1 but also that it is already reached after 9 min. instead of 30 min. using a conventional tool. Comparing the demand of heating energy for 75 C and 160 C: IsoForm tools need up to 95 % less energy for heating for the present application compared to conventional tools. Fig. 10: Picture by Single / Durotherm for W2 IsoForm1 High precision due to consistent hub-centring of all inserts, mould plates and mould halves against each other The individual concept for standard elements that goes with the tool concept IsoForm renders the most diverse constellations possible: from one cavity in an isolated mould insert to many small cavities in one or numerous mould inserts. With large parts it often happens that only the mould core side is incorporated into an isolated insert and that on the cavity side the entire mould plate without insert is isolated. Fig. 11 The applicability might be individual: However, the thermal isolation from the surrounding tool and the consistent hubcentring (fig. 6) remain unaffected. This allows for the feed temperature of the mould core to be lower than that of the cavity. Considering the speed with which the part shrinks onto the core it is conceivable that the cavity contributes very little to the energy transition from the injected plastic mass. An adapted temperature regulation is therefore even more necessary as well as a temperature of the mould surface according to the prerequisites given by the material supplier. Different thermal expansion that might occur can mostly be compensated thanks to the hub-centring (fig. 11) of all components.

6 High lifetime and low deflexion due to an adequate system of ejection plates The form of the ejection plates is due to functional aspects and only allows for low distances between the resulting supports in the supporting ejection box. Anxiety columns, that are frequently used, are no longer necessary provided that the dimensions of the intermediate plate were calculated accordingly. The innovative design of the ejection frame results in a maximum support of the mould plate and thus reduces all deflexion. An unwanted deflexion resulting in flash formation in the tool is therefore history. Fig. 12 Multiple use of the principal mould unit at a high precision Certainly, multiple use also offers an interesting perspective for the current trend for a large variety of models at small quantities. Fig. 13 Fig. 14 For multiple use, the IsoForm program offers variations of standard elements where the inserts can be exchanged from the separation level. These inserts both benefit from the precise centring and can be changed simply and quickly.

7 HeiNo Gate System For the cold runner range (thermoplastic elastomers) and other applications (thermosets / elastomers), an appropriate gate system was established. Here, you see a version of the distributor insert within the mould plate. The insert comes in different sizes and designs. It does without the central retaining undercut, uses two non-centred undercuts instead and already provides for a mandatory dead runner for the cold slug. Additionally, a special gate insert with tunnel connection was designed. Fig. 16 This has been optimised rheologically and combines the dead end recess with a smooth transition to an almost circular connection to the part. Due to the special contour of the Fig. 15 transition there are no sharp edges transversely to the flow direction. This allows for the lowest possible shear rate within the plastic material provided that the correct gate diameter is maintained (table). For materials that need shearing, other geometries were included into the "HeiNo range of products. In combination with high abrasion-resistant steels, we also offer lowwear solutions for materials reinforced by more than 50 % glass fibres. The entire tunnel gate program is also available as electrode versions. from Nonnenmann. Additional solutions include screwing, clamping and / or regulation of the temperature of gate inserts. HeiNo Ventilation Comprehensive ventilation of the mould in and around the cavity is for example made possible by HeiNo insert and ejector ventilation using groove and chamfer for ventilation or by HeiNo ventilation inserts. Fig. 17 Fig. 18 Fig. 19

8 Fascination Mould Design a new concept for a good future in mould design. IsoForm - The New Isolated Tool Concept for thermoplastic elastomers, thermosets, elastomers and diecasting Isolated mould inserts reduce the costs and efforts for temperature regulation, improve the energy-efficiency considerably and allow for initiating the injection moulding process quickly. A consistent hub-centring of all inserts, mould plates and mould halves against each other ensures high precision. The innovative design of the ejection frame results in a maximum support of the mould plate and thus reduces deflexion. The gate system optimises shearing during the filling phase which makes optimum surfaces at low distortion possible. Reduce mistakes and produce even more cost-efficiently in the future Using the IsoForm tool concept by Konstruktionsbüro Hein GmbH combined with injection moulding simulation and appropriate sensors within the tool for adjusting the injection moulding process sets a standard that eliminates almost all sources of error. Energy and time are important and sustainable factors for calculating injection moulding tools, pressure moulding tools, die-casting tools and rubber moulds. The new tool concept therefore definitely is an excellent investment for the future. Konstruktionsbüro Hein GmbH Konstruktionsbüro Hein GmbH Rudolf Hein; Henrik Bertel +49 (0) info@kb-hein.de Nonnenmann GmbH Karl Nachtrieb +49 (0) karl.nachtrieb@nonnenmann-gmbh.de Supported by the German Federal Ministry of Economics and Technology based on a decision by the German Federal Parliament