180919 stoba Vertreterpräsentation ENFilter sizes 1. Stage 2. Stage Chamber 1 10 µm --Chamber 2 10...

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

Transcript of 180919 stoba Vertreterpräsentation ENFilter sizes 1. Stage 2. Stage Chamber 1 10 µm --Chamber 2 10...

Page 1: 180919 stoba Vertreterpräsentation ENFilter 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 Filter unit Absolute filter ...

“Customization for ECM,

Automation and

Workpiece specific cleaning”

Dipl. WI-Ing (FH)

Robert Schnitzler(Vertrieb / Sales)

www.stoba-Memmingen.de

Sondermaschinen

Memmingen

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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

Summary

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Revenue: ~ 180,0 Mio €

Employee: ~ 950

Company structure

Facility: Memmingen

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Stoba key competences

Stoba

ECM/PECM Technology

Machine for Elektro-Chemical

Machininig (ECM/PECM)

Compact CNC 5-Axes Milling

machine

Fixture, Automation

& Cleaning machine

Stoba

Milling-/Drilling

Technology

CNC 5-Axes Precise-Laser-Drilling

machine

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αduoαmono

1x workstation 2x workstation

σPECM

PECM sinking machine

αbasic

ECM Entry solution

Overview stoba-portfolio

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αmono

Full automated

customized

machine

Semi automatedFull automated standard

machine

β β

Overview stoba-portfolio

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δ3D ε

3D-ECM Multistep Cleaning

machine

Overview stoba-portfolio

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FlexMill MultiMill Focus

Overview stoba- customized portfolio

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ECM

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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.

Electro chemical machining (ECM)

- +Electrolyte with

a mixture of water and salt

U=I=el I=el

Cathode Anod

Iion

+-

Men+Me(OH)nn(OH)-2e- H2 2H+

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Fixture „bottom unit “Cathode

Workpiece+-

Fixture „upper unit“

Anode

Ele

ktro

lyte

Electro chemical machining (ECM)

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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.

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Sodium nitrate NaNo3

or

Sodium Chlorid NaCl

Pressure: 0,5 – 15 bar

Flow rate: 0,1 – 300 l/min

Temperature: 20-30°C

pH-Value: 6,5-7,5 pH

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Key parameters for ECM:

Anode

Cathode

Electrolyte

Temperature

Conductivity Electrolyte

Current (DC)

Fixture

Working gap

Current: 1 – 4000 A

Voltage: 1 – 59 V (DC)

Electro chemical machining (ECM)

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ECM-Prozessbestandteile

Workpiece specific fixture

Possible Pre-cleaning ECM machine

Filter press

High-Tech Automation

Post-cleaning, Drying, Passivation

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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

Properties of ECM

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Forming – Injection technology Polishing – Medical

technology

PECM ECM Drilling – Injection

technology

Deburring hydraulic block

Proven solutions ECM machining

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Deburring – High pressureDeburring – Valve technology

(Deburring of the hole intersections)

Chamfering – Gear technology

Proven solutions ECM machining

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Automotive, Injection

Automotive, Gear box

Powertrain

Medical

Die and Molding

Energy

Sectors ECM/PECM – Deburing/Sinking/Drilling

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ECM

Sinking

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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.

ECM Sinking

Ele

ktrolyte

Workpiece

Cathode

Feed

Front gap

Side gap

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PECM

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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. 0.05 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.

PECM

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Cleaning

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Air cleanliness

Handling

ChamberFiltration

technology

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Realization post cleaning machine

Pre-cleaning

ECM Deburring

Post-cleaning & Drying

Clean room

Automation

Customized solutions in cleaning for the

process Laser and ECM

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Pre-cleaning

ECM Deburring

Post-cleaning & Drying

Clean room

Air cleanliness

Planing of the airway from inside to

outside

Erection of pressure areas

Integration of clean room systems

Own regulation for control of the air power

AirwayExcess pressure

5 mBar

Atmosphere

1000 mBar

Excess

pressure

10 mBar

Excess

pressure

15 mBar

Customer

Clean room

Target: constant Air flow and

pressure

Realization post cleaning machine

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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

Realization post cleaning machine

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Chamber

Loading station

4x Cleaning

2x Drying

Unloading station

Segmentation of the chambers:

R1

R4R3

R2

T1

T2

Realization post cleaning machine

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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

Realization post cleaning machine

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R1

R4R3

R2

T1

T2

Float cleaning Splash cleaning

Realization post cleaning machine

Chamber

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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

Realization post cleaning machine

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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

Lance

Realization post cleaning machine

Chamber

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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

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Floating

Realization post cleaning machine

Chamber

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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 µmFilter unit

Absolute filter

Realization post cleaning machine

Filtration technology

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Drying process

Mode

Chamber 5 Hot air drying

Chamber 6 Vacuum drying

View Drying equipment

Leakage testing

Assembly

Drying

Realization post cleaning machine

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Drying process

Mode

Chamber 5 Hot air drying

Chamber 6 Vacuum drying

Hot air chamber

Heißlufttemperaturen bis 130°C

Heißluft im Umlauf durch Bypass

Integrierte Abtropfwanne

Taktzeit: 68 sek.

Realization post cleaning machine

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Drying process

Mode

Chamber 5 Hot air drying

Chamber 6 Vacuum drying

stiff vacuum chamber with ribs

Vacuum pump with max. 200m³/h

Depression up to 10 mbar possible

Desired exit temperature: 40 - 45°C

1 bar

10 mbar

Realization post cleaning machine

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Sauberkeitsanforderungen an Motorenbauteile

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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 Alle Partikel

Bearbeitungsspäne Flusen, Fasern

Schleifmittelrückstände Lackpartikel

Metallhydroxide Kunststoffpartikel

Keramik Harte Partikel

Partikel im kraftstoffführenden Bereich

25 µm < x < 400 µm

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Realized Project

Customer specification

Part HD-Kraftstoffverteiler-Leiste

Material 1.4301

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)

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Required technical cleanliness

Particle size(metallic / non-metallic)

Amount

25 … 50 µm 150

50 … 100 µm 100

100 … 150 µm 33

150 … 200 µm 10

200 … 400 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

Realized Project

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Cleanliness results to VDA Bd. 19

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Cleanliness results to VDA Bd. 19

Biggest metallic particle Second biggest metallic particle

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Biggest non-metallic particle Second biggest non-metallic particle

Cleanliness results to VDA Bd. 19

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Reinigungsergebnisse nach VDA Bd. 19

Largest Fiber

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Laser

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Laser radiation

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Function Laser

Laser

source

Galvo mirror

Focus lens

Nozzle

Workpiece

Protective gas

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Process varieties at laser drilling:

Helix drillTrepan drillPercussion drill

Process possibilities

Single pulse drill

Pulse energy, Pulse duration Precision

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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

The laser beam hits in percussion drilling in several pulses with a shorter duration and energy always on the same

position of the workpiece.

Trepan drill

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 drill

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.

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Difference of Pulse technic

Micro-Laser

(Pulse duration 10-6 sec)

Femto-Laser

(Pulse duration 10-15 sec)

UKP-Laser remove the material as a

plasma

Micro-Laser remove the material as a melt

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Process shape examples

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Sharp-edged hole exit at all angles. No backwall

damage.

Almost sharp-edged hole entry. With

highest contour accuracy.

Hole diameter 146 – 207µm Hole diameter 167µm

Proven Solution

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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

Identification and Advantages of Laser drilling

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Thank you for your attention

Dipl. WI-Ing (FH)

Robert Schnitzler(Vertrieb / Sales)

Datum: 28.06.2018 www.stoba-Memmingen.de

Sondermaschinen

Memmingen