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“Customization for ECM,
Automation and
Workpiece specific cleaning”
Dipl. WI-Ing (FH)
Robert Schnitzler(Vertrieb / Sales)
www.stoba-Memmingen.de
Sondermaschinen
Memmingen
1. Introduction of stoba Group and stoba Sondermaschinen
2. Introduction in ECM (Electro chemical machining)
3. Introduction in ECM sinking
4. Introduction in PECM
5. Introduction in Cleaning
6. Introduction in Laser
2
Summary
3
Revenue: ~ 180,0 Mio €
Employee: ~ 950
Company structure
Facility: Memmingen
4
Stoba key competences
Stoba
ECM/PECM Technology
Machine for Elektro-Chemical
Machininig (ECM/PECM)
Compact CNC 5-Axes Milling
machine
Fixture, Automation
& Cleaning machine
Stoba
Milling-/Drilling
Technology
CNC 5-Axes Precise-Laser-Drilling
machine
5
αduoαmono
1x workstation 2x workstation
σPECM
PECM sinking machine
αbasic
ECM Entry solution
Overview stoba-portfolio
6
αmono
Full automated
customized
machine
Semi automatedFull automated standard
machine
β β
Overview stoba-portfolio
7
δ3D ε
3D-ECM Multistep Cleaning
machine
Overview stoba-portfolio
8
FlexMill MultiMill Focus
Overview stoba- customized portfolio
9
ECM
10
What is ECM?
Non-conventional removal process of electrically conductive materials (metals) with external voltage source
(= targeted dissolution of the metal ions).
The process of electrochemical machining is achieved by an external current source, which causes a forced charge and
mass transfer between the poled as the anode (+) workpiece and the cathode (-) tool via the electrolyte as the active
medium.
At the positively poled workpiece (+) material is removed (oxidation). Depending on the pH, the metal cations passing
into the electrolyte either remain dissolved or precipitate in the form of insoluble metal hydroxides. At the cathode (-),
elements are reduced by the electrical charge exchange such as e.g. in the production of water with evolution of
hydrogen.
Electro chemical machining (ECM)
- +Electrolyte with
a mixture of water and salt
U=I=el I=el
Cathode Anod
Iion
+-
Men+Me(OH)nn(OH)-2e- H2 2H+
11
Fixture „bottom unit “Cathode
Workpiece+-
Fixture „upper unit“
Anode
Ele
ktro
lyte
Electro chemical machining (ECM)
12
What is a burr?
Burrs are sharp edges of a metallic workpiece resulting from a machining or manufacturing process. On the one hand,
these can impair the function of the end product, on the other hand they can cause considerable risks of injury such as
deep cuts.
During turning or milling operations, burrs occur due to material displacement at the cutting edge.
Sodium nitrate NaNo3
or
Sodium Chlorid NaCl
Pressure: 0,5 – 15 bar
Flow rate: 0,1 – 300 l/min
Temperature: 20-30°C
pH-Value: 6,5-7,5 pH
13
Key parameters for ECM:
Anode
Cathode
Electrolyte
Temperature
Conductivity Electrolyte
Current (DC)
Fixture
Working gap
Current: 1 – 4000 A
Voltage: 1 – 59 V (DC)
Electro chemical machining (ECM)
14
ECM-Prozessbestandteile
Workpiece specific fixture
Possible Pre-cleaning ECM machine
Filter press
High-Tech Automation
Post-cleaning, Drying, Passivation
15
Process information:
Pure anodic removal (=workpiece specific), meaning nearly no wear at the tool
No contact between the workpieces and tool
No thermal structure influences
No micro burrs
Realization of good surface conditions
The removal rate depends on the metal alloy and the necessary current
All metal materials are processable as for example chromium-nickel steel, Inconel, high alloyed materials
High productivity in case of multi clamping of workpieces short cycle times possible
High process stability and safety
High precision and repeatability through the self developed ECM generator
No harmful tension at the workpieces
Hardness, viscosity and machinability of the workpieces will not influence the ECM process
Properties of ECM
16
Forming – Injection technology Polishing – Medical
technology
PECM ECM Drilling – Injection
technology
Deburring hydraulic block
Proven solutions ECM machining
17
Deburring – High pressureDeburring – Valve technology
(Deburring of the hole intersections)
Chamfering – Gear technology
Proven solutions ECM machining
18
Automotive, Injection
Automotive, Gear box
Powertrain
Medical
Die and Molding
Energy
Sectors ECM/PECM – Deburing/Sinking/Drilling
19
ECM
Sinking
20
What is ECM sinking?
The ECM sinking is based on the principle of the static ECM process. However, during ECM sinking there is a feed
movement between the tool (cathode) and the workpiece (anode), which turns the process to dynamic ECM process.
The working gab will be approx. 0,2 mm. As a result, a wide variety of geometries can be processed into the
workpieces.
The feed rate of the cathode depends on the ECM removal rate. Therefore, ECM sinking requires a synchronization of
feed and removal.
ECM Sinking
Ele
ktrolyte
Workpiece
Cathode
Feed
Front gap
Side gap
21
PECM
22
What is PECM?
The PECM is based on the principle of the static ECM process. However, in PECM there is a feed movement between
the tool (cathode) and the workpiece (anode), which turn forms a dynamic ECM process. This is superimposed by a
sinusoidal lifting movement of the cathode. The lifting movement is needed to get fresh electrolyte into the working
gap. The working gap is approx. 0.05 mm.
As a result, a wide variety of geometries can be precisely processed into the workpieces.
The feed rate of the cathode depends on the removal rate and the required accuracy. Therefore the PECM requires a
synchronization of the feed rate and the offset.
PECM
23
Cleaning
Air cleanliness
Handling
ChamberFiltration
technology
24
Realization post cleaning machine
Pre-cleaning
ECM Deburring
Post-cleaning & Drying
Clean room
Automation
Customized solutions in cleaning for the
process Laser and ECM
25
Pre-cleaning
ECM Deburring
Post-cleaning & Drying
Clean room
Air cleanliness
Planing of the airway from inside to
outside
Erection of pressure areas
Integration of clean room systems
Own regulation for control of the air power
AirwayExcess pressure
5 mBar
Atmosphere
1000 mBar
Excess
pressure
10 mBar
Excess
pressure
15 mBar
Customer
Clean room
Target: constant Air flow and
pressure
Realization post cleaning machine
26
Handling
Rotary machine with 4-fold clamping of the workpieces
The workpieces are clamped in the workpiece carrier
Every cycle the workpiece carrier will be cleaned
Realization post cleaning machine
27
Chamber
Loading station
4x Cleaning
2x Drying
Unloading station
Segmentation of the chambers:
R1
R4R3
R2
T1
T2
Realization post cleaning machine
28
Chamber
Wet chemical cleaning with splash and float cleaning
Integrated nozzle bar and lances
High pressure and flow rate 267 l/min
View: Cleaning chamber
Realization post cleaning machine
29
R1
R4R3
R2
T1
T2
Float cleaning Splash cleaning
Realization post cleaning machine
Chamber
30
Chamber
Cleaning strategy
Inside Outside Media
Chamber 1 Splashing Nozzle chemical
Chamber 2 Floating Nozzle chemical
Chamber 3 Splashing Nozzle Purified
water
Chamber 4 Floating Nozzle Purified
water
Floating Splashing
Realization post cleaning machine
31
Cleaning strategy
Inside Outside Media
Chamber 1 Splashing Nozzle chemical
Chamber 2 Floating Nozzle chemical
Chamber 3 Splashing Nozzle Purified
water
Chamber 4 Floating Nozzle Purified water
Lance
Realization post cleaning machine
Chamber
Cleaning strategy
Inside Outside Media
Chamber 1 Splashing Nozzle chemical
Chamber 2 Floating Nozzle chemical
Chamber 3 Splashing Nozzle Purified water
Chamber 4 Floating Nozzle Purified
water
32
Floating
Realization post cleaning machine
Chamber
33
Filter sizes
1. Stage 2. Stage
Chamber 1 10 µm --
Chamber 2 10 µm --
Chamber 3 1 µm 5 µm
Chamber 4 1 µm 5 µmFilter unit
Absolute filter
Realization post cleaning machine
Filtration technology
34
Drying process
Mode
Chamber 5 Hot air drying
Chamber 6 Vacuum drying
View Drying equipment
Leakage testing
Assembly
Drying
Realization post cleaning machine
35
Drying process
Mode
Chamber 5 Hot air drying
Chamber 6 Vacuum drying
Hot air chamber
Heißlufttemperaturen bis 130°C
Heißluft im Umlauf durch Bypass
Integrierte Abtropfwanne
Taktzeit: 68 sek.
Realization post cleaning machine
36
Drying process
Mode
Chamber 5 Hot air drying
Chamber 6 Vacuum drying
stiff vacuum chamber with ribs
Vacuum pump with max. 200m³/h
Depression up to 10 mbar possible
Desired exit temperature: 40 - 45°C
1 bar
10 mbar
Realization post cleaning machine
Sauberkeitsanforderungen an Motorenbauteile
37
Definition Restschmutz:
Schädigende Partikel mit denen Bauteile nach deren Fertigstellung kontaminiert
sind und die den weiteren Fertigungsprozess bzw. die korrekte Funktion des Bauteiles beeinträchtigen
oder verhindern können.
Harte Partikel Alle Partikel
Bearbeitungsspäne Flusen, Fasern
Schleifmittelrückstände Lackpartikel
Metallhydroxide Kunststoffpartikel
Keramik Harte Partikel
Partikel im kraftstoffführenden Bereich
25 µm < x < 400 µm
38
Realized Project
Customer specification
Part HD-Kraftstoffverteiler-Leiste
Material 1.4301
Dimension L: 400 mm (Ø 20 mm)
Application Deburring, Cleaning, Drying
Output 0,8 - 1,0 Mio.
Types 2 (without set up)
Cycle time < 25 sec per piece
4-6 connection holes (Ø 1,00 – 3,50 mm)
39
Required technical cleanliness
Particle size(metallic / non-metallic)
Amount
25 … 50 µm 150
50 … 100 µm 100
100 … 150 µm 33
150 … 200 µm 10
200 … 400 µm 2
> 400 µm 0
Fibers 10
Cleanliness inspection only at fuel touching areas
Particle size: Detail in length
Defined Amount: Pieces
Maximum width of the 5 biggest particles: 50 µm
Realized Project
40
Cleanliness results to VDA Bd. 19
41
Cleanliness results to VDA Bd. 19
Biggest metallic particle Second biggest metallic particle
42
Biggest non-metallic particle Second biggest non-metallic particle
Cleanliness results to VDA Bd. 19
43
Reinigungsergebnisse nach VDA Bd. 19
Largest Fiber
44
Laser
Laser radiation
45
Function Laser
Laser
source
Galvo mirror
Focus lens
Nozzle
Workpiece
Protective gas
46
Process varieties at laser drilling:
Helix drillTrepan drillPercussion drill
Process possibilities
Single pulse drill
Pulse energy, Pulse duration Precision
47
Differences of the Process possibilities
Single pulse drill
In single-pulse drilling, the laser beam penetrates the material in one pulse. The energy effect decreases with
increasing borehole depth.
Percussion drill
The laser beam hits in percussion drilling in several pulses with a shorter duration and energy always on the same
position of the workpiece.
Trepan drill
The operation of trepanning is similar to percussion drilling, with the difference that first a start hole must be
created, which increases by rotating movements of the laser.
Helix drill
Helix drilling is also based on percussion drilling. The only difference is the rotating movement of the laser beam,
which removes the material in a spiral pattern.
48
Difference of Pulse technic
Micro-Laser
(Pulse duration 10-6 sec)
Femto-Laser
(Pulse duration 10-15 sec)
UKP-Laser remove the material as a
plasma
Micro-Laser remove the material as a melt
49
Process shape examples
50
Sharp-edged hole exit at all angles. No backwall
damage.
Almost sharp-edged hole entry. With
highest contour accuracy.
Hole diameter 146 – 207µm Hole diameter 167µm
Proven Solution
51
Advantages: No remaining burrs
Low heat influence
Perfect dimensional accuracy
High cutting speed
Perfect material utilization
Identifications: Non-contacting machining
No force effect
Drilling of hard materials
Contour possibilities (angular,
round, oval)
Hole sizes beginning at ø 25 µm
Identification and Advantages of Laser drilling
Thank you for your attention
Dipl. WI-Ing (FH)
Robert Schnitzler(Vertrieb / Sales)
Datum: 28.06.2018 www.stoba-Memmingen.de
Sondermaschinen
Memmingen