“ The system makes setting-up processes on our Lumex range of machines repeatable, accurate, dependable and efficient, ” says Holger Hermann, head of application engineering for linear fabricate technology at Matsuura Europe GmbH in Wiesbaden, Germany .
Matsuura ’ s Lumex hybrid linear fabricate systems efficaciously mix laser sinter ( SLS ) and high-speed mill ( HSM ). Through this combination, components can be fully processed on one car with extra finish work only necessary in particular circumstances .
In the method developed by Matsuura on two Lumex machines, alloy gunpowder is turned into 3D shapes through layered selective laser fade in the powder bed. In this summons, a mirror galvanometer precisely directs character lasers – 500 or 1,000W in lastingness, depending on the design of the machine – to the intended detail.
Reading: A case in point – PES Media
After each die, the scrapers re-distribute the alloy powder on the machine table that has been moved downwards and away. On beginning impressions, this is a conventional 3D print work, however, after ten-spot powder layers each with a thickness of 50µm, something different happens – the base or substrate plate doesn ’ thyroxine move downwards again to apply the adjacent level of gunpowder. alternatively, it remains in its original position .
then, the milling head accelerates the cutter to up to 45,000rpm, moves along the forbidden shape and rough-machines a part with an R2 ball cutter for example. “ The mill can ’ thymine so far take the part down to finished size because the hot substantial is placid cooling and the geometry is consequently in a submit of flux, ” Mr Hermann explains .
“ This march is repeated for all ten-spot layers generated by the laser. A instrument changer holds 20 tools at the ready for this function, including pre-cutters for rough-machining the level generated by laser melt. After three times ten layers – or 1.5mm – the final examination contour is created with the eat up tool at the points where cool has taken place .
“ Comparing to a pure AM process ; here we achieve greater preciseness, particularly in places which are subsequently difficult or impossible to access, ” he adds. “ The summons goes down to 0.005mm and Rz 3.5µm compared to 0.05mm and Rz 25 µm. ”
so far the care has been on the visible operations at the top area of the machine board – what has been going on in the substrate remains hidden from the observer – but is no less critical. The zero-point clamp modules particularly designed by AMF for additive fabrication can accelerate the set-up processes involved .
For case, very high temperatures are reached during a 3D impression process : at the melting point of the metallic element in the powder bed it can be ampere high as 1,400°C. tied if the clamp modules are underneath a 30mm compact plate, temperatures of up to 150° and higher hush can occur.
AMF uses seals and media which can withstand these temperatures. To ensure process dependability and repeat accuracy international relations and security network ’ thyroxine compromised due to temperature fluctuations, AMF uses cautiously selected materials and processes such as season surfaces on its zero-point clamp modules .
On its Lumex machines, Matsuura uses K5.3 built-in clamp modules from AMF in its additive fabrication processes. They open pneumatically at just 5 bar function pressure via a individual association. Five modules pick up the clamp bolts, which are housed under the 3D base plate for conduct workpiece clamp : “ This is because our customers in tool and mold gain wear ’ t subsequently cut the base plate off from the finished 3D product at all, ” stresses Mr Herrmann, who cites warping as the main cause behind this .
The K5.3 built-in clamp modules offer draw-in forces of 1.5kN and holding forces of 13kN. Locking is performed through spring force so that, following the opening and interpolation of the clamp bolts, the press pipes can be disconnected at any time .
due to the optimum contour of the clamp bolt, tilt-free retraction and annex, and thus secure lock of the clamp modules, is ensured – even if the plate has been positioned at a little incline. The optional, incorporate blow-out mechanism of the clamp modules and a contact manipulate mechanism for querying as part of automatize processes are not installed on the Lumex systems but can be supplied by AMF if required .
Mr Herman is delighted with the speed advantages offered by the AMF zero luff system : “ By reducing production time by up to 65 % such as with injection molding tools for case with the hybrid method, we are offering our Lumex customers a significant efficiency advantage, ” he enthuses. “ here, the zero-point system offers an optimum solution for many applications which contributes to the overall efficiency of the entire action. ”
Before AMF ’ s sales mastermind – who has a longstanding kinship with Matsuura – suggested the zero-point solution, clamp was performed manually via conventional technology. Back then, the basal plate was bolted down to the machine table with four screws and aligned every time with the dial gauge and calibrated with a zero-point detector. This cumbersome calibration process had to be performed repeatedly for every part .
“ With the AMF Zero-Point system, the set-up time can be reduced by 90 %, ” Mr Hermann concludes .