The tool making division at medium-sized business Toolcraft put a new machining centre into operation at the start of 2013. The fully air-conditioned machining centre is equipped with the following machinery: an Exeron HSC 600 5-axis milling machine with Awex 50/5 alternator, an Exeron HSC 300 3-axis milling machine with Awex 50/5 alternator and an Exeron EDM 313 electric discharge machine with Awex 50/5 alternator, two Exeron EDM 312 electric discharge machines with Erowa ERM robots and an Exeron EDM 310 electric discharge machine. Two Zeiss Contura 3D coordinate measuring machines are also used in the measuring department, which obtain measured data directly from the design department. Pallet cleaning is carried out by an Erowa robot system. The main feature of this machining centre is the automated management of all tool parts and electrodes in a UPC pallet system based on Certa automation software.
According to Klaus Dörr, Head of Mould Making and Injection Moulding, the new centre enables cutting-edge automated tool making with which the flow of parts can be centrally managed. This means they can produce around the clock when needed, with high throughput and fast delivery times. Around EUR 1.5 million were invested in the new concept according to Klaus Dörr. The new system means that not only can a timely flow of parts be achieved, but tool design can also be included in production: tool designers can send measuring points and tolerances directly to the Zeiss measuring equipment. Linking design and production results in continuous quality monitoring. A high technical level with high flow rates and a significant reduction of manual work is achieved with this kind of industrialised tool making.
Automated tool making and injection mould making under one roof
The mould making and injection moulding division at Toolcraft has its roots in model railway making. At the time, miniatures in this field already set the highest standards in attention to detail and manufacturing knowledge. After this industry ‘migrated’ out of Germany, Toolcraft turned to hearing aid manufacturers to supply them with complete assemblies. All major manufacturers in Europe, America and Asia are now customers. Standards in this sector are very high, says Klaus Dörr: ‘The tiny components make very high demands on tool making, but also on production and assembly. The required clearances and accuracy of fit of the parts are at a level which is much easier to achieve in other industries.’ Small parts for hearing aids range from a 0.01g to 5g charge weight. In order to be able to offer complete solutions as part of their precision strategy, Toolcraft has a small parts injection department with 20 injection moulding machines and 30 staff in addition to their mould making department with a total of 18 machines and 70 staff. In addition, machines for running-in and series start are available separately.
The highest demands on precision
Hearing aid requirements are many and varied: in addition to the high precision required for these miniatures, accuracy of fit is also highly prized. Customers require small clearances from 10 – 20 μ, a value which is nowhere near as low in many other industries. In terms of injection technology, the parts are very remarkable. This is why warping is a particular issue. So as to keep this as low as possible, Toolcraft relies on conformal cooling in tools: on this front, conformal cooling provides ‘easing’ at relevant points on the tool. ‘A very effective method,’ says Klaus Dörr, ‘in which the strengths of classic tool making production and the generative production of laser melting with metals provide combined solutions, making for impressive production technology. It’s also clear that parts like these demand precision rather than the lowest possible cycle speeds.’
Firmenkontakt und Herausgeber der Meldung:
MBFZ toolcraft GmbH
Handelsstraße 1
91166 Georgensgmünd
Telefon: +49 (9172) 6956-0
Telefax: +49 (9172) 6956-560
http://www.toolcraft.de
Ansprechpartner:
Bernd Krebs
Tina Hartmann-H'Lawatscheck
+49 (9172) 6956-172
Dateianlagen:
Automatisierter Werkzeugbau_automated tool making