Use new technology of sand mold milling

  • Time:
  • Click:352
  • source:LAURENDA CNC Machining
Abandon the traditional method that sandbox works, use milling sand mold however, use part of car prototype automobile body through unremitting ground this kind makes new technology, this can make a these parts immediately not only, and can reduce a few auxiliary equipment and cost, discharge these charge completely perhaps. "Current, of prototype part cast a model OK and fast, be made with very low fare, " the automobile body task of center of trial production of joint-stock company of Ao Di car manages Germany and experiment a say of manufacturing chief Dr. Friedrich Burgahn. "Because, use go up in molding sand box directly the new technology of milling sand mold, not only can working procedure of leave out much talk, and because cancelled so called disappear model, also need polystyrene expanded plastics no longer. And nonexistent also the cleared charge of appearance of countless polystyrene styrofoam pattern. " it is however before this, still use the technique that having bigger difference with ideal, current, the Shi Mei that uses a convention is arenaceous come through binder and stiffening agent beforehand preparation model base, make its can undertake machining inside molding sand box, get the model with outline tall precision through such treatment. This kind of model can be one-time make, and quality is good, can popularize application, already included application program now. In the foundry of the trial production center of I/EV23 of Ao Di Motor Corporation, will make the automobile body part of prototype by the professional that having rich experience. Each spare parts must want to make a pattern, this mould uses zincic alloy material to be made normally, zincic alloy material is contained 93.

The zinc of 05% , 3.

The aluminium of 9% , 3.

The copper of 0% and 0.

The magnesium of 05% . The melting point of zincic alloy is 430 ℃ . This kind of material compares easy treatment, the character that inspects plank, ply and shape modular circumstance, this kind of mould has particularly good service life. 200 ～ can come true when machining prototype and trial production 500 sample spare parts, the mould of zincic alloy mould is the beauty that use stone arenaceous make. But before is to make appearance of polystyrene styrofoam pattern, this plastic about is in fill up about 15 tons arenaceous model mould is become with negative pressure mould in box, wait for molding sand take out after complete sclerosis, later, appearance serves as this plastic pattern " disappear model " give cleared. Turn into idea reality uses the mould zinc alloy, bulk measurement that looks a part through what milling arises, be in about 1 ～ 2 days shapable sand mold, undertake to its on milling machine cutting is machined later. The light that just has the face finally makes treatment. Those who include a pattern is fluctuant inside, experts should produce prototype every year about -- all sorts of patterns that panel uses are highest can amount to 600, production mould place needs zincic alloy material to amount to 800 ～ 1000 tons. Mr Fridrich Burgahn and his work in the same placing from beginning to end the test that unremitting ground undertakes a mould making and actor chemical industry are made, work through this, although be below the condition that mould breed adds ceaselessly, controallable still the production charge of the mould, still can make charge is reduced even. This aroused trial production center to be in charge of the idea of Mr Robert Oblinger of join technology and industrial robot technology, also made him rise to use industrial robot to undertake on sand mold milling is machined in the attention on professional exposition, the VTT of technical development institute that is the same as Finland continues together research and development machines mode this kind, begin from theory first, subsequently translate into applies actually, make an uses milling sand mold equipment that supports by industrial robot namely. Bulk of molding sand case comes for 2000mm about long, 1600mm reachs 3000mm wide, 400mm reachs 2200mm 600mm is tall, the sandbox of such size can satisfy the need that spare parts of all automobile body creates. Nextpage should choose accordingly particularly or use equipment to have longer the industrial robot of the arm, and the arm of the robot is carried even mix operate main shaft of a report. If whole project theretofore does not have bigger question, so, to using a NC -- data is changed into " contrail of industrial robot shift " special software, for the cutting tool that machines sand mold to choosing to agree with especially, confidence was established on certain level, by a Finnish dimensions not big development business -- company of Simtech system finite liability used ConiferRob program to solve problem of this one software. But to cutting cutting tool, the situation is different, because, the cutting tool supplier with main without still heretofore and manufactory had been engaged in sand mold treatment. The development associate that searchs cutting tool of sand mold milling uses agglomeration metal cutting tool and the carbolic corundum cutting tool that have diamond coat to be in after experiencing experiment failure for many times, ao Di Motor Corporation must seek another development partners. The cutting tool company that found Israel finally -- Iscar (Www.

Iscar.

De) , be in Germany, iscar company place where troops are stationed is in Ettlingen, hold the position of field service personnel by Mr Joachim Schneele, mr Schneele is in charge of Mr AndreasZippel of PKD cutting tool and reamer one case with Iscar company again, become the expert that captures this machines the task. Use to place, the cutting tool that assembles data of stock PKD cutting tool, it is the dinkum and special cutting tool that has the bulk that amounts to 600mm to grow, weight to be as high as 10kg, with Ao Di the experts of Motor Corporation undertake clasp develops this kind of cutting tool. Here, must want to notice, what want milling on molding sand model antrum and the load that electric main shaft allows. The power of electric main shaft is 15kW, turn up 6000r/min. Outfit stock is connected reduce unit of airy interior refrigeration, cold compress air to be able to cool not only PKD cutting tool, and return can blow off the sand that milling comes down. Mr Andreas Zippel and the ball head milling cutter that developed a diameter to be 40mm at the outset in the experts of Ettlingen and the razor blade of pottery and porcelain that suit with workpiece data phase. Although this the experiment got setback, but, the 2nd test that uses a diameter to already undertook for the PKD tool industry of 63mm brought expectant breakthrough however, because, until go up in the round razor blade of PKD at present, what still do not have occurrence edge is bigger wear away. And the cutting tool that experiments before (agglomeration metal and the carbolic corundum that have diamond coat) go up to experiment every time after 3 hours, and same to razor blade of pottery and porcelain all appeared after 3 hours bigger wear away, classics of PKD razor blade experiments for many times, service life of its cutting tool all exceeded 6000 hours far! And also was not shown on edge show wear away phenomenon. The success that ball head milling cutter is using place of PKD razor blade to obtain is farther incentive the technical personnel of Iscar company, accordingly, at present Iscar already developed the corn milling cutter of PKD-SMDT razor blade. All participator expect milling cutter of this kind of corn can improve the manufacturing efficiency of 20% again when milling sand mold, OK and affirmative ground says, returning the research report of the respect of durability of PKD cutting tool that did not concern sand mold milling absolutely at present. Conclusion uses the remarkable result that place of PKD milling cutter achieves, no matter be the trial production center to Ao Di Motor Corporation, still feel very happy to the cutting tool experts of Iscar company, because, still use pair of sand mold without the person in allowing when to await two companies or other and similar wear bead model, make material of cutting tool tatty has undertaken milling is machined easily. So Friedrich Burgahn, Robert Oblinger is mixed l3 of Josef Scher the development between gentleman general and company of Iscar of cutting tool associate cooperates, calling is a kind of very outstanding collaboration, especially this kind of collaboration produced economic result very quickly still. "Because be sand mold milling, we entered a brand-new field. Brought quite great benefit to us, because use new method oneself since, of material purchase, of milling treatment and appearance of polystyrene styrofoam pattern cleared wait for the job but leave out 90% , because of such about we just issue ability to need in special situation, " Mr Friedrich Burgahn explains. Because cancelled the drawing of patterns of processing of the milling of the model, case hardening and sandbox, reduced path or 3 two process now, shortened apparently from this production time. In addition, manufacturing technological process becomes an organic whole oneself now, such easier palms accuse, and have flexible. Another bigger advantage is to be able to use sandbox of molding sand cram to prepare the job, make process has nothing to do with data input or about input. At that time, in Ao Di Motor Corporation, process of sand mold milling is responsible, and it is to undertake automatically completely, especially sandbox swings on height a position undertakes milling, the sand that conduces to milling coming down falls effectively. "Use PKD milling cutter, make us OK will efficient be in with the mould of tall stability in shaping accurately, can use of emersion, such, also make zincic alloy mould becomes accurate. " Mr Friedrich Burgahn is summed up finally, "Logical is we still must reduce surplus for milling treatment, in this the respect still can save handling time, shorten from this production is periodic. Shorten from this production is periodic.. CNC Milling