Workpiece optimized machine solutions for parts cleaning

Transcription

1 Workpiece optimized machine solutions for parts cleaning Dipl. WI-Ing (FH) Muhammer Kör Member of stoba Group Date:

2 Overview Who is stoba & what are the core competences Cleanliness requirements on basis of a realized project Introduction of the realized cutomer project Reached cleaning results Summary

3 Stoba core competences Machines for Electro-Chemical Machining (ECM/PECM) CNC 5-Axis Laser-drilling machining center Stoba ECM/PECM Technology Stoba Milling/Drilling Technology Fixture, automation & cleaning machines CNC 5-Axis compact milling center

4 Cleanliness requirements for engine components General definition residual contamination: Residual contamination consists of solid particles and soluble substances that persist on the surface of the component after the final step in manufacturing. The dirt particles, especially hard particles cause severe damage and reduce the lifetime of the product. Hard particle Machining chips Grinding residues Metal hydroxide Ceramics All particle Fibrous material, Fiber Coating particles Plastic particle Hard particle Definition particle size in engine systems 25 µm < x < 400 µm

5 Realized customer project Customer requirements Part High-pressure fuel distributor Material Dimension Application Annual volume Types Cycle time L: 400 mm (Ø 20 mm) Deburring & cleaning 0,8-1,0 Mio. 2 (without changeover) < 25 sec per part 4-6 hole intersections (Ø 1,00 3,50 mm)

6 Realized customer project Cleanliness requirements Particle size (metallic / nonmetallic) Amount µm µm µm µm µm 2 > 400 µm 0 Fibers 10 Cleanliness measurement only applicable for fuel-touching areas (internal areas) Particle size : Definition in length Amount: Piece Maximum width of 5 biggest particle: 50 µm

7 Manufacturing process steps CNC machining Pre-cleaning Clean room Post-cleaning ECM deburring Neutralisation (desalting) Post-cleaning & drying Part flow Handover clean room Leak test Pre-cleaning desalting ECM deburring

8 Manufacturing process steps Post-cleaning & Drying After pre-cleaning Burrs and dirt residues After ECM deburring Metal hydroxides, salt particles and dirt residues Leak test Assembly

9 Realisation of post-cleaning machine ECM deburring Clean room Air purity Handling Filter technology Chamber Automation Post-cleaning Pre-cleaning

10 Realisation of post-cleaning machine Air purity Post-cleaning Overpressure 5 mbar Air path Air path from inside to outside Setting of compression zones Implementation of clean room units Controller for regulation of the ventilation system performance Clean room Customer clean room Overpressure 15 mbar Overpressure 10 mbar Assembly, leak test and package Atmosphere 1000 mbar ECM deburring Pre-cleaning

11 Realisation of post-cleaning machine Handling Rotary table with 4-fold clamping unit Parts clamping in the workpiece holder Cleaning of the workpiece holder in each flow

12 Realisation of post-cleaning machine Chamber Layout of the chamber Part loading 4x cleaning C4 C3 C2 D1 C1 D2 2x drying (hot air & vacuum) Part unloading

13 Realisation of post-cleaning machine Chamber Wet chemical process with spray and flood cleaning Integrated blast connection and lances High pressure and flow rate (e.g. 267 l/min) View: Cleaning chamber

14 Realisation of post-cleaning machine Chamber C4 D1 D2 C3 C2 C1 Flood cleaning Spray cleaning

15 Realisation of post-cleaning machine Chamber Cleaning strategy Inside Outside Medium Chamber1 Spray Nozzle Chemistry Chamber2 Flood Nozzle Chemistry Chamber3 Spray Nozzle DI-Water Chamber4 Flood Nozzle DI-Water Flooding unit Jet-lance

16 Realisation of post-cleaning machine Chamber Cleaning strategy Inside Outside Medium Chamber1 Lance Nozzle Chemisty Chamber 2 Flooding Nozzle Chemistry Chamber3 Lance Nozzle DI-Water Spraylance Chamber 4 Flooding Nozzle DI-Water

17 Realisation of post-cleaning machine Chamber Cleaning strategy Inside Outside Medium Chamber 1 Lance Nozzle Chemistry Chamber2 Flooding Nozzle Chemistry Flooding unit Chamber 3 Lance Nozzle DI-Water Chamber4 Flooding Nozzle DI-Water

18 Realisation of post-cleaning machine Filter technology Filter size 1. Stage 2. Stage Chamber 1 10 µm -- Chamber 2 10 µm -- Chamber 3 1 µm 5 µm Chamber 4 1 µm 5 µm Filter unit

19 Reached results accord. VDA Bd

20 Reached results accord. VDA Bd. 19 Largest metallic particle Second largest metallic particle

21 Reached results accord. VDA Bd. 19 Largest nonmetallic particle Second largest nonmetallic particle

22 Reached results accord. VDA Bd. 19 Largest fiber

23 Summary Cleaning is more than parts washing Analyzing of the total manufacturing steps before layouting the cleaning machine concept Considering of all influencing parameters according to the cleanliness requirements Stoba experience: Fine-cleaning = Spray-cleaning with lances and nozzles

24 Thank you for your attention Visit us Hall 3 / D56 Stoba Sondermaschinen GmbH Mittereschweg Memmingen Germany