Presentation Mold Technologies...INglass is organized with a unique process and production model...
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Presentation Mold Technologies Speaker: Philippe MAFILLE
Transcript of Presentation Mold Technologies...INglass is organized with a unique process and production model...
Presentation Mold Technologies
Speaker: Philippe MAFILLE
Rheological analysis specialist 12 Thermal detailed analysis specialist 3 Structural analysis specialist 3 Designer 82 KAM- PM 11 Try out and starting mould technicians 12
One Skilled Global Team
100 Engineers focused on advanced analysis for a guarantee of the performance results
INglass is organized with a unique process and production model worldwide This is achieved thanks to the use of the most advanced technology in Europe.
The company has invested in fully automated facilities to work 24/7, to deliver: • Great Accuracy, Reliability and Stability of the production process. • Short delivery time • Consistent Quality Level Wherever your production facilities are located . GLOBALLY
Unique production and process model worldwide
Our Expertise: Rheological and FEM Simulations
“A good result starts from a correct layout definition from the beginning”
Thermal and Structural analysis
Such analysis are realized in order to guarantee, long lasting life of all our components , consistent part weight and low energy consumption
Thermal analysis: Rheological analysis; Filling phase Packing phase Cooling phase Warpage phase Fiber Orientation Gas assistance Injection-compression
Our experts are in the major production centers: • Europe (EMEA) • China (APEC) • Canada/USA (NAFTA) • Brazil (MERCOSUR)
Structural analysis:
THE SOLUTION
SLM - (SELECTIVE LASER MELTING TECHNOLOGY)
Our Expertise: Conformal Cooling by Laser
Mold cooling phase: means 60-75% of the entire cycle time Affects quality of the part
“The end result is an optimized molded part, produced at a lower cost”
SLM MAIN BENEFITS:
Optimal thermal control at the gate and cavity areas means: • Cycle time reduction. • Improved tolerances. • Accurate warpage control. • No stringing or drooling.
• Same mechanical properties as W.1.2311 or W.1.2343 – H13 according to heat treatment;
• Easily Machinable with milling machine, lathe and spark erosion machine (EDM);
• Coating possible
• Laser Weldable
• Gloss Polishing achievable
• Tolerance as built 0,05 mm
Powder Steel properties
• “As built”:
Hardness: 35-37 HRc
Yield strenght: 1000 MPa
• After hardening treatment :
Hardness: from 48 up to 54 HRc
Yield strength : from 1400 up to 1900 MPa
• Mechanical properties:
Our Expertise: Conformal Cooling by 3D Steel SLM Printing
«SOLID» Layout
Insert Rough status Overstock 0,5 mm for fitting into its mold pocket
Insert Finished Status After Polishing After Machining to fit into its mold pocket «Hybrid » Layout
Inserts Layouts by using 3D Steel SLM Printing Technology
1. Toolbase loaded and aligned in our SLM machine
2. SLM 3D Printing process
3 Rough finished SLM inserts ready for final tune up By Toolmaker (fitting+polishing if required)
Distance from surface 2,5 mm Cooling channel 2.0 mm dia
Hybrid Inserts built by using 3D Steel SLM Printing Technology
Summary of ERMO Technologies
Unscrewing System Forced Ejection System
Retractable Core System
In Mold Closing System
Multi-Material Rotation System
Core Back System
‘Tourniquet’ Core System
Butterfly System
In Mold Assembly System
Unscrewing Technology
Principle Thread Ejection by rotating core (Deep Thread/ High Number of Turns)
Cavities number High (128 Cav.)
Cycle Time Depending of the lenght of thread
Mold Cost More expensive than Forced Thread Ejection (approx. 25%)
Operator Skill Level Low
Click here to see the working system
Unscrewing System
(Example ULTRA DOUX Project + on going KERASTASE Project)
Undercut dimension Critical Area to eject
Forced Ejection System
Force Ejection Technology
Principle Undercut Demoulding
Cycle Time Same as traditional Ejection
Mold Cost Lower (no internal lifter)
Operator Skill Level Low
Main Features Simpler Kinematics, Longer reliability
Retractable Core System
Rectractable Core Technology
Principle Manufacturing of a core with retractable lifters (up to 16 cores now)
Cycle Time Same as traditional molds
Mold Cost Approx. + 10% compared to molds with no lifters
Operator Skill Level Low
Main Features One complete part in one shot No real limit for the undercut dimensions (depending of the part dimensions)
Click here to see the working system
IMC Technology
Principle Production of hinge speciality cap
Cavities number High
Cycle Time + 1sec for part closing in the mold
Mold Cost Lower than post-process part closing
Operator Skill Level Low
Main Features One or two hinges possible Reliable System for High Volumes
In Mold Closing System : IMC
Patented: Europe, Americas, Asia
Click here to see the working system
Multi-Material Rotation System
Rotative Technology
Principle Simultaneous injection of several resins is possible thanks to the cavities rotation
Cavities number 32 Cavities with horizontal spin so far
Cycle Time Approx. +2 sec due to mold rotation compared to one shot part
Mold Cost Part Design affected Lower than transfer or two molds
Operator Skill Level Low
Main Features Complex part design One complete component each cycle Time with only one mold Possible Mechanical Grip also with complex resins
Click here to see the working system
Core back System Core Back Technology
Principle Injection of different resins during mold closing phase by core retracting step
Cavities number Also High
Cycle Time Approx. +1 sec compared to one shot component
Mold Cost Lower than transfer or two molds
Operator Skill Level Low
Main Features More cavities than with rotational layout (double) Not possible for all part design
Click here to see the working system
‘Tourniquet’ Core System (Example FRUCTIS Project)
‘Tourniquet’ Core Technology
Principle Production of a 2 shot component by inner rotation core
Cavities number High
Mold Cost Approx. 5% compared to Core back system
Cycle Time Same even if thick part inserts
Operator Skill Level Simple
Main Features More cavities than with rotational layout (double) Specific part design
Patented: Europe, Americas, Asia
Butterfly System
Double Gram SpinStack
Injection Machine Special Dedicated Machine (opposite screws barrels, rotation system integrated in the mold)
Mass Production Level High Volume
Lead Time Identical to rotative molds
Mold Cost Lower cost in case of Bi-injection (suitable for simple parts) Very Specific Part Design Good compromise Mold Price/Part Price
Click here, to see a video Clik here, to see a video of the working system of the working system
1) IMA by cavity rotation 2) IMA by cavity translation
Patented: Europe, Americas, Asia
In Mold Assembly System : IMA
Two possible layouts :
ERMO IMA: Examples
Cube System
Cube Technology
Principle Assembly of 2 different components in same mold
Cavities number High
Mold Cost €€€€€
Operator Skill Level High
Main Features • Longer to reset all equipments after production transfer • Special Dedicated Moulding Machine (vertical spin)
ERMO IMA / TWIN CUBE
ERMO IMA
TWIN CUBE
Principle Assembly of 2 different components in same mold
Production Mass Production for 2 to 15Mio Mass Production for more than 50Mio
Mold Cost €€ €€€€€
Cycle Time +5 to 10% compared to Cube (1 sec on 10 sec)
Devpt Lead Time
Operator Skill Level Low High
Main Features • Easy Production to transfer • Shorter Start-Up compared
to Cube • Standard machine +
Flexible satellite Injection Unit
• Longer to reset all equipments after production transfer
• Special Dedicated Moulding Machine (vertical spin)
MAIN SYNERGIES FOR CUSTOMERS BENEFIT
GLOBAL PRESENCE Sales and Technical SKILLED support available closer to Customer’s site
ONE REFERENCE CONTACT ONLY TO CUSTOMER – PM/KAM Committed to the successfull result of Customer Full Project wherever production is launched
DOUBLE EXPERTISE Main Innovation driver to deliver flexible and customized full bounded solutions
TOTAL WARRANTY PACKAGE We guarantee the complete package assembly and its after-sales follow up
DOUBLE EXPERTISE - GLOBALLY DELIVERED
Our strategy is to optimize the performances and the reliability of the product to share our technological developments to improve our dual knowledge of the injection molding process
