Innovative surface by EDM for the mould industry

Transcription

1 GF Machining Solutions Innovative surface by EDM for the mould industry EDM-MSS F. Goudard /

2 Table of Contents APPLICATION EDM TECHNOLOGY SURFACE QUALITY IMPROVMENTS INNOVATIONS 2

3 GF Machining Solutions APPLICATION APPLICATION 3

4 Market segments Customers worldwide depend on our technologies, application knowhow and process expertise in our five key market segments. Aerospace and Aeronautics Automotive Medical and Dental ICT Electronic components 4 GF Machining Solutions, company presentation 2014

5 Market segments Aerospace and Aeronautics 5

6 Market segments ICT 6

7 GF Machining Solutions EDM TECHNOLOGY 7

8 EDM technology The principle of EDM (Electrical Discharge Machining) is simple. The workpiece and tool are placed in the work position so that they do not touch. A gap remains, filled by the "dielectric." The workpiece and tool are connected to a direct current power source via a cable. A switch is inserted in the connection. When closed, an electrical current is set up between the workpiece and tool

9 EDM method Die-Sinking In die-sinking EDM, the required shape is formed negatively in the metal with a threedimensional electrode. By superimposed movements in the main axes x, y, c, z, the most varied shapes, indentations and cavities are created, such as cannot be achieved by any other machining system.

10 FORM products FORM 2000 VHP FORM 3000 VHP Price / Performance FORM 1000 FORM 2000 HP FORM 3000 HP FORM 200 ms FORM 200 Sp FORM 200 FORM 300 Sp FORM 300 FORM 400 FORM 20 FORM x x x x x 700 Size XY travels

11 FORM 200/ 300/

12 EDM method Wire-Cutting In wire-cutting EDM, the required shape is "computer" stored and passed as comprehensible codes to the machine, which then cuts the shape independently by guiding the wire along the given stretch.

13 CUT Products Price / Performance CUT 1000 / CUT 1000 OilTech CUT 2000 S / CUT 2000 OilTech CUT 200 ms CUT 300 ms CUT 3000 S CUT 200 Sp PROGRESS VP2 CUT 300 Sp PROGRESS VP3 CUT 400 Sp PROGRESS VP4 CUT 20 P CUT 30 P Size 220 x x x x 550 XY travels

14 CUT 2000 S / CUT 3000 S Significant performances in term of speed, surface finish and threading Increase cutting speeds by 30% for roughness Ra 0.2 µm (productivity increased) Better surfaces finish Ra 0.05 µm in Water Machines (CW) Threading small holes with THREADING-EXPERT Integrated Vision Unit Advance with correction of the contour

15 3D Architecture Texturing SURFACE QUALITY IMPROVMENT 15

16 Who is interested to improve the process? Customers doing injection plastic

17 Process to improve #1 Maintain the shiny homogeneity Increase the anti-scratches ability

18 Process to improve #2 Maintenance issues in the injection molding process -> Effectiveness of surface treatments? Problem: many potential treatments exist which cannot be assessed during process due to long testing times needed

19 Impact on the life time of the mold > 300 Mold shots Compound begin to stick. > 400 Mold shots More compound Stick. > 500 Mold shots More compound Stick.

20 Mold is coated

21 But just before the coating

22 Surface quality and homogeneity 50x 100x 200x

23 Customers want to improve the process? Productivity Less maintenance Anti-scratch Repeatability

24 What are they looking for? Better management Friction Corrosion Sticking effect Phisical- Chemichal Sticking Mecanical sticking Roughness

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26 Ejection force measurement Series of test samples produced with different treatments 26

27 Practical tests (3 000 cycles) showing test correlation with real residue results with used polymer: PSU (yellow) ** * Without treatment a-c:h-w TiAlN product 27

28 Friction tests between treated surfaces and plastic polymers

29 Friction tests PSU (at 20 C) coefficient of friction ** 29

30 3D architecture Texturing INNOVATION INNOVATION 30

31 How to categorize a surface? 31

32 How to categorize a surface? 32

33 INNOVATION

34 From a rough to a smooth surface quality New AC-TX spark Traditional spark Same Ra Rsm

35 Electronic microscope images ACTX 14 compared with standard, same Ra

36 How can we help them? 1. More than just traditional Ra 2. To modulate surface dimensions (Rsm, etc.) 3. To provide flexible tool for customer needs. AC-TX parameter 4. By monitoring dedicated parameter we are able to provide different surface texture by keeping the wanted Ra

37 3D surface architecture texturing

38 3D surface architecture texturing provide Flexibility Quality Repeatability Granularity homogeneity

39 Solution: friction tests between plastic polymers and machined surfaces

40 Example: Friction tests PSU (at 20 C) **

41 Basic mold performance indicators Friction test on 3D Architecture Texturing coefficient of friction Ra 1.4 µm Ra 1.4 µm Ra 1.4 µm Rsm 98 µm Rsm 80 µm Rsm 214 µm Highest productivity potential Highest potential for residue minimization

42 Example: Friction tests PSU (at 20 C) **

43 Basic mold performance indicators Permability tests on 3D Architecture Texturing Hydro/ oleophopby angle Ra 1.4 µm Ra 1.4 µm Ra 1.4 µm Rsm 98 µm Rsm 80 µm Rsm 214 µm + - Highest productivity potential Highest potential for residue minimization

44 3D surface architecture texturing Automatic generation settings Graphite/Steel technology Copper steel on progress Basic ACTX scale range: VDI14,18,23,24,26,32,40 and 60. Surface range up to 150 x 70 mm

45 3D surface architecture texturing Our customer already confirm: 30% less maintenance costs Less mold Cost of reparation The quality improve The mass production capability

46 3D surface architecture texturing And you?

47 THANKS 47