Customization for ECM, Automation and Workpiece specific cleaning

Transcription

1 Sondermaschinen Memmingen Customization for ECM, Automation and Workpiece specific cleaning Dipl. WI-Ing (FH) Robert Schnitzler (Vertrieb / Sales)

2 Summary 1. Introduction of stoba Group and stoba Sondermaschinen 2. Introduction in ECM (Electro chemical machining) 3. Introduction in ECM sinking 4. Introduction in PECM 5. Introduction in Cleaning 6. Introduction in Laser 2

3 Company structure Revenue: Employee: Facility: ~ 180,0 Mio ~ 950 Memmingen 3

4 Stoba key competences Machine for Elektro-Chemical Machininig (ECM/PECM) CNC 5-Axes Precise-Laser-Drilling machine Stoba ECM/PECM Technology Stoba Milling-/Drilling Technology Fixture, Automation & Cleaning machine Compact CNC 5-Axes Milling machine 4

5 Overview stoba-portfolio α basic α mono α duo σ PECM ECM Entry solution 1x workstation 2x workstation PECM sinking machine 5

6 Overview stoba-portfolio α mono β β Full automated standard machine Full automated customized machine Semi automated 6

7 Overview stoba-portfolio δ 3D ε 3D-ECM Multistep Cleaning machine 7

8 Overview stoba- customized portfolio FlexMill MultiMill Focus 8

9 ECM 9

10 Electro chemical machining (ECM) What is ECM? Non-conventional removal process of electrically conductive materials (metals) with external voltage source (= targeted dissolution of the metal ions). The process of electrochemical machining is achieved by an external current source, which causes a forced charge and mass transfer between the poled as the anode (+) workpiece and the cathode (-) tool via the electrolyte as the active medium. At the positively poled workpiece (+) material is removed (oxidation). Depending on the ph, the metal cations passing into the electrolyte either remain dissolved or precipitate in the form of insoluble metal hydroxides. At the cathode (-), elements are reduced by the electrical charge exchange such as e.g. in the production of water with evolution of hydrogen. Cathode Anod I =el + - U= I =el I ion - + 2e - HElectrolyte 2 2H + n(oh) Me(OH) with - n Me n+ a mixture of water and salt 10

11 Electro chemical machining (ECM) Anode Fixture upper unit + - Elektrolyte Workpiece Cathode Fixture bottom unit 11

12 What is a burr? Burrs are sharp edges of a metallic workpiece resulting from a machining or manufacturing process. On the one hand, these can impair the function of the end product, on the other hand they can cause considerable risks of injury such as deep cuts. During turning or milling operations, burrs occur due to material displacement at the cutting edge. 12

13 Electro chemical machining (ECM) Key parameters for ECM: Anode Cathode Electrolyte Temperature Sodium nitrate NaNo 3 or Sodium Chlorid NaCl Pressure: 0,5 15 bar Flow rate: 0,1 300 l/min Temperature: C ph-value: 6,5-7,5 ph Current: A Voltage: 1 59 V (DC) Conductivity Electrolyte Current (DC) Fixture Working gap 13

14 ECM-Prozessbestandteile High-Tech Automation Filter press Workpiece specific fixture Possible Pre-cleaning ECM machine Post-cleaning, Drying, Passivation 14

15 Properties of ECM Process information: Pure anodic removal (=workpiece specific), meaning nearly no wear at the tool No contact between the workpieces and tool No thermal structure influences No micro burrs Realization of good surface conditions The removal rate depends on the metal alloy and the necessary current All metal materials are processable as for example chromium-nickel steel, Inconel, high alloyed materials High productivity in case of multi clamping of workpieces short cycle times possible High process stability and safety High precision and repeatability through the self developed ECM generator No harmful tension at the workpieces Hardness, viscosity and machinability of the workpieces will not influence the ECM process 15

16 Proven solutions ECM machining Forming Injection technology Polishing Medical technology Deburring hydraulic block PECM ECM Drilling Injection technology 16

17 Proven solutions ECM machining Deburring High pressure Deburring Valve technology (Deburring of the hole intersections) Chamfering Gear technology 17

18 Sectors ECM/PECM Deburing/Sinking/Drilling Automotive, Injection Automotive, Gear box Powertrain Medical Die and Molding Energy 18

19 ECM Sinking 19

20 ECM Sinking What is ECM sinking? The ECM sinking is based on the principle of the static ECM process. However, during ECM sinking there is a feed movement between the tool (cathode) and the workpiece (anode), which turns the process to dynamic ECM process. The working gab will be approx. 0,2 mm. As a result, a wide variety of geometries can be processed into the workpieces. The feed rate of the cathode depends on the ECM removal rate. Therefore, ECM sinking requires a synchronization of feed and removal. Feed Cathode Side gap Elektrolyte Front gap Workpiece 20

21 PECM 21

22 PECM What is PECM? The PECM is based on the principle of the static ECM process. However, in PECM there is a feed movement between the tool (cathode) and the workpiece (anode), which turn forms a dynamic ECM process. This is superimposed by a sinusoidal lifting movement of the cathode. The lifting movement is needed to get fresh electrolyte into the working gap. The working gap is approx mm. As a result, a wide variety of geometries can be precisely processed into the workpieces. The feed rate of the cathode depends on the removal rate and the required accuracy. Therefore the PECM requires a synchronization of the feed rate and the offset. 22

23 Cleaning 23

24 Realization post cleaning machine ECM Deburring Clean room Air cleanliness Handling Filtration technology Chamber Automation Post-cleaning & Drying Pre-cleaning Customized solutions in cleaning for the process Laser and ECM 24

25 Realization post cleaning machine Post-cleaning & Drying Air cleanliness Target: constant Air flow and pressure Excess pressure 5 mbar Airway Planing of the airway from inside to outside Erection of pressure areas Clean room Customer Clean room Excess pressure 10 mbar Atmosphere 1000 mbar Pre-cleaning Integration of clean room systems Own regulation for control of the air power Excess pressure 15 mbar ECM Deburring 25

26 Realization post cleaning machine Handling Rotary machine with 4-fold clamping of the workpieces The workpieces are clamped in the workpiece carrier Every cycle the workpiece carrier will be cleaned 26

27 Realization post cleaning machine Chamber Segmentation of the chambers: Loading station 4x Cleaning T1 R4 T2 R3 R2 R1 2x Drying Unloading station 27

28 Realization post cleaning machine Chamber Wet chemical cleaning with splash and float cleaning Integrated nozzle bar and lances High pressure and flow rate 267 l/min View: Cleaning chamber 28

29 Realization post cleaning machine Chamber T1 R4 T2 R3 R2 R1 Float cleaning Splash cleaning 29

30 Realization post cleaning machine Chamber Cleaning strategy Inside Outside Media Chamber 1 Splashing Nozzle chemical Chamber 2 Floating Nozzle chemical Chamber 3 Splashing Nozzle Purified water Chamber 4 Floating Nozzle Purified water Floating Splashing 30

31 Realization post cleaning machine Chamber Cleaning strategy Inside Outside Media Chamber 1 Splashing Nozzle chemical Chamber 2 Floating Nozzle chemical Lance Chamber 3 Splashing Nozzle Purified water Chamber 4 Floating Nozzle Purified water 31

32 Realization post cleaning machine Chamber Cleaning strategy Inside Outside Media Chamber 1 Splashing Nozzle chemical Chamber 2 Floating Nozzle chemical Floating Chamber 3 Splashing Nozzle Purified water Chamber 4 Floating Nozzle Purified water 32

33 Realization post cleaning machine Filtration technology Filter sizes 1. Stage 2. Stage Chamber 1 10 µm -- Chamber 2 10 µm -- Chamber 3 1 µm 5 µm Chamber 4 1 µm 5 µm Absolute filter Filter unit 33

34 Realization post cleaning machine Drying process Chamber 5 Chamber 6 Mode Hot air drying Vacuum drying Drying Leakage testing Assembly View Drying equipment 34

35 Realization post cleaning machine Drying process Chamber 5 Chamber 6 Mode Hot air drying Vacuum drying Heißlufttemperaturen bis 130 C Heißluft im Umlauf durch Bypass Integrierte Abtropfwanne Taktzeit: 68 sek. Hot air chamber 35

36 Realization post cleaning machine Drying process Mode Chamber 5 Hot air drying Chamber 6 Vacuum drying 1 bar 10 mbar Vacuum pump with max. 200m³/h Depression up to 10 mbar possible Desired exit temperature: C stiff vacuum chamber with ribs 36

37 Sauberkeitsanforderungen an Motorenbauteile Definition Restschmutz: Schädigende Partikel mit denen Bauteile nach deren Fertigstellung kontaminiert sind und die den weiteren Fertigungsprozess bzw. die korrekte Funktion des Bauteiles beeinträchtigen oder verhindern können. Harte Partikel Bearbeitungsspäne Schleifmittelrückstände Metallhydroxide Keramik Alle Partikel Flusen, Fasern Lackpartikel Kunststoffpartikel Harte Partikel Partikel im kraftstoffführenden Bereich 25 µm < x < 400 µm 37

38 Realized Project Customer specification Part HD-Kraftstoffverteiler-Leiste Material Dimension L: 400 mm (Ø 20 mm) Application Deburring, Cleaning, Drying Output 0,8-1,0 Mio. Types 2 (without set up) Cycle time < 25 sec per piece 4-6 connection holes (Ø 1,00 3,50 mm) 38

39 Realized Project Required technical cleanliness Particle size (metallic / non-metallic) Amount µm µm µm µm µm 2 > 400 µm 0 Fibers 10 Cleanliness inspection only at fuel touching areas Particle size: Detail in length Defined Amount: Pieces Maximum width of the 5 biggest particles: 50 µm 39

40 Cleanliness results to VDA Bd

41 Cleanliness results to VDA Bd. 19 Biggest metallic particle Second biggest metallic particle 41

42 Cleanliness results to VDA Bd. 19 Biggest non-metallic particle Second biggest non-metallic particle 42

43 Reinigungsergebnisse nach VDA Bd. 19 Largest Fiber 43

44 Laser 44

45 Function Laser Laser source Laser radiation Galvo mirror Protective gas Focus lens Nozzle Workpiece 45

46 Process possibilities Process varieties at laser drilling: Single pulse drill Percussion drill Trepan drill Helix drill Pulse energy, Pulse duration Precision 46

47 Differences of the Process possibilities Single pulse drill In single-pulse drilling, the laser beam penetrates the material in one pulse. The energy effect decreases with increasing borehole depth. Percussion drill Trepan drill Helix drill The laser beam hits in percussion drilling in several pulses with a shorter duration and energy always on the same position of the workpiece. The operation of trepanning is similar to percussion drilling, with the difference that first a start hole must be created, which increases by rotating movements of the laser. Helix drilling is also based on percussion drilling. The only difference is the rotating movement of the laser beam, which removes the material in a spiral pattern. 47

48 Difference of Pulse technic Micro-Laser (Pulse duration 10-6 sec) Femto-Laser (Pulse duration sec) Micro-Laser remove the material as a melt UKP-Laser remove the material as a plasma 48

49 Process shape examples 49

50 Proven Solution Hole diameter µm Hole diameter 167µm Sharp-edged hole exit at all angles. No backwall damage. Almost sharp-edged hole entry. With highest contour accuracy. 50

51 Identification and Advantages of Laser drilling Advantages: No remaining burrs Low heat influence Perfect dimensional accuracy High cutting speed Perfect material utilization Identifications: Non-contacting machining No force effect Drilling of hard materials Contour possibilities (angular, round, oval) Hole sizes beginning at ø 25 µm 51

52 Thank you for your attention Sondermaschinen Memmingen Dipl. WI-Ing (FH) Robert Schnitzler (Vertrieb / Sales) Datum: