Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Lightweight structures, the future technology - Thermoforming and injection moulding in one single mould

28.09.2010
Making its début at K 2010 in Düsseldorf (27th October until 3rd November) will be a combined thermoforming and injection mould developed by Georg Kaufmann Formenbau AG, Busslingen/Switzerland. This so-called organo sheet mould will be demonstrated by KraussMaffei Technologies GmbH (Stand C24 in Hall 15) in fully automatic operation on a CX 300-1400 IMC. The mould is used for the production of a lightweight structural component.

This dynamically loaded component for a passenger car is produced from organo sheet – a glass fibre reinforced semifinished thermoplastic composite – and stiffened with moulded-on ribs. The organo sheet is first thermoformed in the mould and then, in the same mould, provided with the moulded-on stiffening ribs.

This innovative combination of thermoforming and injection moulding processes requires a production system in which the individual process stages are exactly coordinated and synchronized with each other. This is where the organo sheet mould plays an essential role in terms of both product quality and process reliability. For the first stage of the process – the thermoforming of the organo sheet – the cut-to-size sheet, which has been preheated and is therefore very soft and unstable, must first be positioned in the mould with absolute, reproducible accuracy. The mould closing operation commences with the advance stroke of a female mould insert, which presses the organo sheet onto the male mould half and holds it there. The actual thermoforming operation now takes place: the sheet is drawn over the male mould half and its peripheral edge is held in place by means of clamping strips that are shaped three-dimensionally so as to match the contours of the moulded part. These clamping strips must be set with extreme precision in order to allow the hot organo sheet to flow freely without sustaining any damage or deterioration.

The mould remains in its closed position at the end of the thermoforming process. The melt for the moulded-on stiffening ribs, consisting of a glass fibre reinforced polymer, is injected via three injection nozzles and bonds completely with the organo sheet. The melt flow-ways ensure in addition that those parts of the structural component that could not be filled during the thermoforming operation are now fully moulded to shape.

All told, as many as six companies and organizations were involved in this future-oriented, technology-bridging project, the results of which are now to be presented at K 2010. Despite the complexity of this involvement, the project was realized within the very short period of only six months. Within three months of receiving the initial component specifications for the design of the mould, for example, Kaufmann was already commencing the mould trials in its own pilot facility.

This combined thermoforming and injection mould for the processing of organo sheet is equipped with more than a dozen sensors for pressure and temperature measurement. They serve not only to monitor the flow of the organo sheet during the thermoforming operation, the injection of the polymer melt and the complete moulding-to-shape of the structural component and they are necessary to make these operations better understandable for future applications. Further organo sheet moulds will likewise be equipped with – albeit considerably fewer – sensors, as they are absolutely indispensable when it comes to process monitoring and quality documentation in applications involving the production of safety-relevant parts.

Innovation through partnership
This project demonstrates quite impressively how it is possible for even a project involving many partners to be realized quickly and successfully all the way through to series production. Involved in this technology-bridging project, besides KraussMaffei Technologies GmbH and Kaufmann, were Jacob Composite GmbH, Audi AG, Lanxess Deutschland GmbH and Bond-Laminates GmbH.

In addition, when it came to optimizing the processing sequences in the mould, specific know-how in the fields of temperature control, hot runner technology and measuring technology was contributed respectively by the following firms: gwk Gesellschaft Wärme Kältetechnik mbH, Incoe Europe and Kistler Instrumente AG.

Further information:
Roger Kaufmann, Georg Kaufmann Formenbau AG
Rugghölzli 3, CH-5453 Busslingen/Switzerland
Phone: +41 (0) 56/485 65 60, Fax: +41 (0) 56/496 54 00
E-Mail: r.kaufmann@gktool.ch

Editorial contact and voucher copies:
Dr. Diether Burkhardt, KONSENS Public Relations GmbH & Co. KG,
Hans-Kudlich-Straße 25, D-64823 Groß-Umstadt
Phone: +49 (0) 60 78/93 63-0, Fax: +49 (0) 60 78/93 63-20
E-Mail: mail@konsens.de

Ursula Herrmann | Konsens Public Relations
Further information:
http://www.gktool.ch
http://www.konsens.de/kaufmann.html

More articles from Machine Engineering:

nachricht PRESTO – Highly Dynamic Powerhouses
15.05.2017 | JULABO GmbH

nachricht Making lightweight construction suitable for series production
24.04.2017 | Laser Zentrum Hannover e.V.

All articles from Machine Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Can we see monkeys from space? Emerging technologies to map biodiversity

An international team of scientists has proposed a new multi-disciplinary approach in which an array of new technologies will allow us to map biodiversity and the risks that wildlife is facing at the scale of whole landscapes. The findings are published in Nature Ecology and Evolution. This international research is led by the Kunming Institute of Zoology from China, University of East Anglia, University of Leicester and the Leibniz Institute for Zoo and Wildlife Research.

Using a combination of satellite and ground data, the team proposes that it is now possible to map biodiversity with an accuracy that has not been previously...

Im Focus: Climate satellite: Tracking methane with robust laser technology

Heatwaves in the Arctic, longer periods of vegetation in Europe, severe floods in West Africa – starting in 2021, scientists want to explore the emissions of the greenhouse gas methane with the German-French satellite MERLIN. This is made possible by a new robust laser system of the Fraunhofer Institute for Laser Technology ILT in Aachen, which achieves unprecedented measurement accuracy.

Methane is primarily the result of the decomposition of organic matter. The gas has a 25 times greater warming potential than carbon dioxide, but is not as...

Im Focus: How protons move through a fuel cell

Hydrogen is regarded as the energy source of the future: It is produced with solar power and can be used to generate heat and electricity in fuel cells. Empa researchers have now succeeded in decoding the movement of hydrogen ions in crystals – a key step towards more efficient energy conversion in the hydrogen industry of tomorrow.

As charge carriers, electrons and ions play the leading role in electrochemical energy storage devices and converters such as batteries and fuel cells. Proton...

Im Focus: A unique data centre for cosmological simulations

Scientists from the Excellence Cluster Universe at the Ludwig-Maximilians-Universität Munich have establised "Cosmowebportal", a unique data centre for cosmological simulations located at the Leibniz Supercomputing Centre (LRZ) of the Bavarian Academy of Sciences. The complete results of a series of large hydrodynamical cosmological simulations are available, with data volumes typically exceeding several hundred terabytes. Scientists worldwide can interactively explore these complex simulations via a web interface and directly access the results.

With current telescopes, scientists can observe our Universe’s galaxies and galaxy clusters and their distribution along an invisible cosmic web. From the...

Im Focus: Scientists develop molecular thermometer for contactless measurement using infrared light

Temperature measurements possible even on the smallest scale / Molecular ruby for use in material sciences, biology, and medicine

Chemists at Johannes Gutenberg University Mainz (JGU) in cooperation with researchers of the German Federal Institute for Materials Research and Testing (BAM)...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Plants are networkers

19.06.2017 | Event News

Digital Survival Training for Executives

13.06.2017 | Event News

Global Learning Council Summit 2017

13.06.2017 | Event News

 
Latest News

Touch Displays WAY-AX and WAY-DX by WayCon

27.06.2017 | Power and Electrical Engineering

Drones that drive

27.06.2017 | Information Technology

Ultra-compact phase modulators based on graphene plasmons

27.06.2017 | Physics and Astronomy

VideoLinks
B2B-VideoLinks
More VideoLinks >>>