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 More functionalities: Microstructuring large surfaces with a UV-laser system
05.07.2018 | Fraunhofer-Institut für Lasertechnik ILT

nachricht A factory to go
04.07.2018 | Fraunhofer Institute for Manufacturing Engineering and Automation IPA

All articles from Machine Engineering >>>

The most recent press releases about innovation >>>

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

Im Focus: Unraveling the nature of 'whistlers' from space in the lab

A new study sheds light on how ultralow frequency radio waves and plasmas interact

Scientists at the University of California, Los Angeles present new research on a curious cosmic phenomenon known as "whistlers" -- very low frequency packets...

Im Focus: New interactive machine learning tool makes car designs more aerodynamic

Scientists develop first tool to use machine learning methods to compute flow around interactively designable 3D objects. Tool will be presented at this year’s prestigious SIGGRAPH conference.

When engineers or designers want to test the aerodynamic properties of the newly designed shape of a car, airplane, or other object, they would normally model...

Im Focus: Robots as 'pump attendants': TU Graz develops robot-controlled rapid charging system for e-vehicles

Researchers from TU Graz and their industry partners have unveiled a world first: the prototype of a robot-controlled, high-speed combined charging system (CCS) for electric vehicles that enables series charging of cars in various parking positions.

Global demand for electric vehicles is forecast to rise sharply: by 2025, the number of new vehicle registrations is expected to reach 25 million per year....

Im Focus: The “TRiC” to folding actin

Proteins must be folded correctly to fulfill their molecular functions in cells. Molecular assistants called chaperones help proteins exploit their inbuilt folding potential and reach the correct three-dimensional structure. Researchers at the Max Planck Institute of Biochemistry (MPIB) have demonstrated that actin, the most abundant protein in higher developed cells, does not have the inbuilt potential to fold and instead requires special assistance to fold into its active state. The chaperone TRiC uses a previously undescribed mechanism to perform actin folding. The study was recently published in the journal Cell.

Actin is the most abundant protein in highly developed cells and has diverse functions in processes like cell stabilization, cell division and muscle...

Im Focus: Lining up surprising behaviors of superconductor with one of the world's strongest magnets

Scientists have discovered that the electrical resistance of a copper-oxide compound depends on the magnetic field in a very unusual way -- a finding that could help direct the search for materials that can perfectly conduct electricity at room temperatur

What happens when really powerful magnets--capable of producing magnetic fields nearly two million times stronger than Earth's--are applied to materials that...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Within reach of the Universe

08.08.2018 | Event News

A journey through the history of microscopy – new exhibition opens at the MDC

27.07.2018 | Event News

2018 Work Research Conference

25.07.2018 | Event News

 
Latest News

Unraveling the nature of 'whistlers' from space in the lab

15.08.2018 | Physics and Astronomy

Diving robots find Antarctic winter seas exhale surprising amounts of carbon dioxide

15.08.2018 | Earth Sciences

Early opaque universe linked to galaxy scarcity

15.08.2018 | Physics and Astronomy

VideoLinks
Science & Research
Overview of more VideoLinks >>>