Concept Laser Industry Specific Solutions

Transcription

1 Concept Laser Industry Specific Solutions Mould Advantages of the LaserCUSING process Front End Software/ - interfaces Machine Solutions Materials Technologies QM system Post treatment Case studies Seite 1 Hofmann Innovation Group

2 Individual solutions for the tool and mould making industry Plastic injection moulding Aluminium die- casting Quelle: Siegfried Hofmann Werkzeugbau GmbH Seite 2 Hofmann Innovation Group

3 LaserCUSING provides For the tool and mould maker: Reduction of the post- treatment procedures (roughing work and pre-finishing is no longer required) Manufacturing of LaserCUSING - inserts within a few days reduction of the development time Delivery of optimal cooled tools Competitive advantage through innovative technologies Seite 3 Hofmann Innovation Group

4 LaserCUSING provides For the injection moulding/ aluminium die- casting companies: Less distortion/ blow holes Reduction of the scrap rate Production of high-quality plastic and aluminium parts competitive advantage Shorter cycle times (If applicable saving of one injection moulding system or die-casting system as well as one complete tool at a constant duration of the project) cost saving For the end customer: Cycle time reduction between % Reduction of the cost per unit Quelle: Siegfried Hofmann Werkzeugbau GmbH High quality products Seite 4 Hofmann Innovation Group

5 Front end software/ -interfaces 3D/CAD-design software CATIA/ AutoCAD/ Unigraphics construction of the tool insert and design of the cooling channels Simulation of the flow conditions Magics software (Materialise) Preparation of the data (create support structures, afterwards slicing of the data) LaserCUSING system Seite 5 Hofmann Innovation Group

6 Machine solutions M1 cusing Target group: small components Build envelope: 250 x 250 x 250 mm Laser system: 200 Watt fibre laser M3 linear Target group: Big components Build envelope: 300 x 350 x 300 mm Laser system: watt fibre laser Seite 6 Hofmann Innovation Group

7 LaserCUSING materials CL 20ES (1.4404)/ stainless steel Acid and corrosion resistant Stainless steel for components for pre-production moulds CL 50WS (1.2709)/ hot-work steel Hot- work steel for components for plastic injection moulds and aluminium die-casting CL 91RW Hard stainless steel with high chrome content For mould components for high volume injection moulding of packaging and medical products Seite 7 Hofmann Innovation Group

8 Technology of the hybrid construction method The formative residual geometry, incl. the cooling channel, is built onto a basic body made from steel by means of LaserCUSING This hybrid type of construction has proven to be the fastest and most economical solution in many cases Quelle: Siegfried Hofmann Werkzeugbau GmbH The hybrid construction method was developed and patented by Concept Laser Seite 8 Hofmann Innovation Group

9 Technology of parallel and surface cooling Optimised cooling channel design with targeted local change in temperature Elimination of dead flow zones no heating of cooling water dynamic and uniform cooling Cooling within 2-3mm of the mould contour surface The parallel and surface cooling was developed and patented by Werkzeugbau Siegfried Hofmann GmbH Quelle: Siegfried Hofmann Werkzeugbau GmbH Seite 9 Hofmann Innovation Group

10 Technology contour pin (ejector pin) Contour pin (ejector pin) with integrated air cooling Large cooling surface for ideal heat transfer Maximum cooling effect at the front end of the contour pin Maximum strength and stiffness of the contour pins caused by the solid structure of helix and contour pin This process was developed and patented by Werkzeugbau Siegfried Hofmann GmbH Seite 10 Hofmann Innovation Group

11 Technology QM system Real-time inspection of the melt pool Online laser and performance monitoring Software module for analysis and report generating after the build process Redundant monitoring and control of the oxygen concentration in the process gas atmosphere Quelle: Siegfried Hofmann Werkzeugbau GmbH Analysis of the powder quality and excellent preservation of the powder quality with our external automatic sieving station Seite 11 Hofmann Innovation Group

12 Post- treatment Heat-treatment Microblasting/ shoot peening Conventional machining, like CNC milling, fine finishing (no roughing and pre-finishing necessary) Post build EDM finish machining Grinding Welding Polishing Seite 12 Hofmann Innovation Group

13 Case study 1: Insert for injection moulding tool Production process conventional 1,5 h data preparation/ programming 0,5 h preparing machine 90 h production time (30 h machine operation time 3.75 working days) 4 h drilling 84 h hardening (hardening plant) Total production time: 180 hours Quelle: W. Faßnacht Werkzeug- und Formenbau GmbH Seite 13 Hofmann Innovation Group

14 Case study 1: Insert for injection moulding tool Manufacturing system: M1 cusing Laser system: Fiber laser 200 W Material: CL 50WS (1.2709) Field of application: Serial tool for injection moulding Machine customer: W. Faßnacht Werkzeug- und Formenbau Production process generative 3 h data preparation (inclusive construction of cooling channels) 0,5 h preparing machine 60 h production time (2,5 working days, because the machine works 24 h/day) 2 h Remove from the building plate 24 h Heat- treatment (tempering furnaces in-house) Quelle: W. Faßnacht Werkzeug- und Formenbau GmbH Total production time: 94 hours Seite 14 Hofmann Innovation Group

15 Comparison of production costs Case study 1: Insert for injection moulding tool conventional generative data preparation/ programming material preparing machine manufacturing time remove from building plate drilling heat- treatment production costs ( ) Seite 15 Hofmann Innovation Group

16 Comparison of production time Case study 1: insert for injection moulding tool convetnional generative data preparation/ programming preparing machine production time remove from building plate drilling production time (h) heat- treatment Seite 16 Hofmann Innovation Group

17 Case study 1: insert for injection moulding tool Advantages due to the use of LaserCUSING - technology Conformal cooling in both domes possible: Short cycle times Reduction of unit costs Competitive advantage Less warpage Better product quality Competitive advantage Quelle: W. Faßnacht Werkzeug- und Formenbau GmbH Seite 17 Hofmann Innovation Group

18 Case study 2: Insert for injection moulding tool Production process conventional 2,5 h data preparation/ programming 0,5 h preparing machine 9 h manufacturing time 5 h drilling 24 h hardening Total production time: 41 hours Quelle: G Plast Ltd. conventional generative Seite 18 Hofmann Innovation Group

19 Case study 2: Insert for injection moulding tool Manufacturing system: M3 linear Laser system: Fiber laser 200 W Material: CL 50WS (1.2709) Field of application: Serial tool for injection moulding Machine customer: G Plast Ltd. Production process generative 2,5 h data preparation (inclusive construction of cooling channels) 6 h manufacturing of the hybrid basic body (milling/ drilling) 0,5 h preparing machine 8 h manufacturing time 24 h heat- treatment (tempering furnaces) Quelle: G Plast Ltd. conventional generative Total production time: 41 hours Seite 19 Hofmann Innovation Group

20 Comparison of production costs Case study 2: Insert for injection moulding tool conventional generative data preparation/ programming material manufacturing of the hybrid basic body preparing machine manufacturing time remove from building plate drilling heat- treatment production costs ( ) Seite 20 Hofmann Innovation Group

21 Comparison of production time Case study 2: insert for injection moulding tool conventional generative data preparation/ programming manufacturing of the hybrid basic body Preparing machine manufacturing time remove from building plate drilling heat-treatment Fertigungszeit (h) Seite 21 Hofmann Innovation Group

22 Case study 2: insert for injection moulding tool Advantages due to the use of LaserCUSING - technology Implementation of a conformal cooling has the following benefits: Reduction of the cycle time from 24 s to 18 s = 25 % Reduction of unit costs Competitive advantage Less warpage Better product quality Competitive advantage conventional generative Seite 22 Hofmann Innovation Group

23 Thank you for your attention! For further question, please feel free to contact us. Mr. Oliver Edelmann Head of Sales & Marketing Concept Laser GmbH An der Zeil 8 D Lichtenfels T +49 (0) 9571 / F +49 (0) 9571 / Seite 23 Hofmann Innovation Group