our team / contact information - konstruktionsbüro hein · entire range of services, consulting...

Konstruktionsbüro Hein GmbH – Your partner for solutions

Our team / contact information

We are a team of specialists with professional backgrounds in practice. We strive for innovations, challenges and fair co-operation.

Address: Phone: Fax:

Konstruktionsbüro Hein GmbH Marschstraße 25 D-31535 Neustadt (near Hanover) Germany +49 (0) 50 32 / 63 15 1 +49 (0) 50 32 / 63 11 6

Home:

E-mail:

E-mail – Technology workshop:

www.KB-Hein.de

[email protected]

[email protected] (Nur für TT)

Data exchange: ftp-Server (Zugangsinfo per E-Mail)

How to reach us (map): www.KB-Hein.de

Konstruktionsbüro Hein GmbH – Your partner for solutions Product development / product optimisation

3

Description:

Co-operation project „Koralle“ (Euromold 2007)

Ophthalmoscope with 26 lenses

Product development or optimisation of your workpiece’s geometry – whatever the task is, we will assist you with our entire range of services, consulting and training with regard to innovative ideas, choice of material(s), procedures and technologies up to the implementation of a production ensuring process reliablity. We can offer you a single service as well as a complete service. The properties of the workpiece will be designed optimally according to your specifications using FEM analysis and injection moulding simulation. Product development for plastic parts are effected plastics-oriented with averaged tolerances and draft angles. Assembled parts are examined using computer tomography.

Your advantage:

• cost-reduction for tool design • reduced cycle times • better quality of the workpiece • shorter project time • considerable reduction of possible

mistakes

Insert moulded PCB

Contact socket -

no burrs on the inside despite filigree separations

Otoscope


FEM analysis For strength - acoustics – dynamics

4

Description:

Simulation instead of trial-and-error using FEM– (finite elements method) analysis

For almost all materials (metal, glass, plastics).

FEM systems for calculating strength are generally divided into “linear“ and “non-linear“ approaches. The “non-linear“ approach is closest to reality when plastic parts are concerned.

Your advantage:

Parts characteristics can already be examined and analysed before the part is actually being manufactured.

Collision observations are ensured using work movements and may be verified in retrospect using computer tomography.

Fixing of media-conducting pipes

Detail of a seal

Application:

Sealing behaviour Acoustics Thermal insulation Dynamic deformation Considerations regarding strength Unwinding behaviour

Required data:

3D data, load points, stress-strain curves of the material


Prototyping / prototooling

5

On demand we are able to provide you with a list for each material indicating all material properties and prameters regarding strength (e-Modul). Prototypes and/or small batches can be manufactured from elastomers (also rubber) and thermoplastic materials to thermosetting plastics and even using metal pressure moulding.

Description:

1) Using the SLS technology parts on the basis of PA12 materials can be manufactured in a favourable price-performance ratio in small batch numbers. The parts (see pic. on the left) show the typical rough surface and may be coloured with some limitations.

2) Injection moulded parts from pilot tools or

experimental tools (see pic. below) already have most of the properties of the series production parts and may be produced with a good quality surface depending on the part design. For most applications, materials can be supplied in the desired colour and strength.

3) Parts from vacuum moulding are mostly formed on a PU material basis. Colouring can only approximate the final colour for series production. Strength can be dimensioned for high loads using glass fibres.


Step 1 Injection moulding simulation

6

Description:

An injection moulding simulation shows filling and shrinkage while including the influence of the tool (e.g. temperature regulation) – before the tool has actually been designed. The simulation allows for recognising possible defects of the moulded part at an early stage thus providing the basis for parts optimisation.

Your advantage:

• higher processing window at the machine

• calculable process window • reduced reengineering • early detection of part defects • cost reduction • easier planning of through-time • controlled and reduced

distortion • early recognition of weld lines

and air traps • optimum design of feed gate • low shut-off pressure

cross member of approx. 1.4 m length

cross member with temperature regulation of the tool

Required data:

• 3D data (e.g. step files) • exact name of material or

rheological data of material • 2D or 3D data of the actual

state inside the tool (temperature regulation and feed)


Step 2 Parts optimisation

7

Description:

On the basis of the results from injection moulding simulation the workpiece can now be optimised. This may include: • process optimisation • geometrical optimisation • material Optimisation • flow Optimisation • feed optimisation • temperature regulation close to

the contour • seperate inserts for temperature

regulation against „hot spots“ • modified seperation for

ventilation • negative correction • optimised packing pressure • alternative production technologies

Your advantage:

• lower production costs • better part quality • faster project cycle • bigger process window • reduced distortion

Pictures by Hirschmann Electronics (überzeichnet dargestellt)

before after

Required data:

You provide us with your solids as well as the data of adjacent parts which we need for optimisation suggestions. Also, the exact name of the material including rheological and mechanical data are required.


Step 3 Temperature regulation close to the contour

8

Description:

In an injection moulding simulation the temperature regulation is already being dimensioned before the tool itself has been designed. The simulation informs about the heat exchange on the tool surfaces and about its influences on the product. The temperature regulation system is designed in order to be effective close to the contour using either drilling, laser melting, vacuum brazing or special materials.

Your advantage:

• short cycle time • reduced distortion • less wear at the tool • adhesions on the tool are

reduced • high quality of moulded part

General:

The correct temperature of the female mould wall is crucial for obtaining a good part quality. Any plastic material has its own determined mould wall surface temperature that shold be attained if possible.

(Pictures by Phoenix Contact / Blomberg)


Laser melting for inserts for temperature regulation

9

Description:

The tool inserts that are manufactured using this method already integrate temperature regulation close to the contour. They are made of resilient hot work steels (hardness of more than HRC 54) using metal powder in a laser melting process (layer composition). The minimum thickness of a layer is 0.025 mm (2008). We initiated vapour diffusion tests (see image on the left) using pressurised water of up to 150°C that proved a diffusion resistance of 100%. 2 manufacturers (2 samples) had thicknesses of up to 0.5 mm.

Your advantage:

Temperature regulation close to the contour in narrow and hot areas with resilient mould inserts.

Required data:

Please note:

The geometries to be produced are processed using an STL file. The roughness of the surface due to the temperature regulation process is smoothed using a grinding paste and/or coating and ensures the temperature regulation together with appropriate temperature control units.

The outside contour should include an allowance for finishing.


Mould design

10

Description:

3-disc tool for thread-spindling-off

Tool design e.g. for: injection moulding tools,

hot press tools,

pressure moulding tools, elastomer moulds

Tool with slide bar redirection GIT tool for charger tray

Special procedures:

vacuum brazing for inserts (upper discs)

8

Examples: multi-component;

sandwich; foaming;

tandem solutions; collapsible cores;

unscrewing solutions;

transfer moulding;

gas injection;

gas cooling;

gas counter-pressure;

external gas moulding;

water injection


NC programming

11

Description:

We offer: • complete service from design to

production

• elekcrode design

• NC programs

• CAD/CAM service considering the workshop

• innovative milling strategies for your

requirements

(Pictures by OpenMind)

General:

For a start: CAM service on your premises. We adapt the NC programs according to your specifications!


Gas injection technology GIT

12

Description:

With the aid of cross sections the gas is guided to the relevant areas where it compensates volume contraction. Thus, the gas assumes the role of the packing pressure at a constant level for the entire workpiece.

Your advantage:

• controlled packing pressure • tension-free and straight part • better cooling effect • low shut-off pressure • reliable process at a high quality

Scope of application:

• for parts with different wall thicknesses • for parts that need to be produced with

low pressure and low distortion

Polarisation films on the overhead projector (see picture on the left) expose the lower potential for tensions in the workpiece with GIT.

cap, pictures by

Phoenix Contact


WIT Water injection technology

13

Description:

Injection inlet

For water injection, the excellent thermal conductivity of water is used to achieve a favourable cycle. Different procedures such as partial filling or auxiliary cavities can be applied. The picture on the left depicts the small inlet and outlet orifice for water injection with a blind hole. The centre-left picture shows the homogenous wall thicknesses that are produced.

Your advantage:

• short cycle times for appropriate geometries

Handle with recesses Partner project of companies Stieler and Hein

With this special WIT process (example: handle), the part is partially filled with water which is then pressed, at high pressure, into the blind hole that has been formed. The water is then extracted well-controlled from the part in order that the part leaves the tool almost dry.

Please note:

Chances and limits of water injection are:

1) Only round geometries such as pipes for the passage of media, can be manufactured with relatively constant wall thickness.

2) If a clustering of the mass occurs a shrinkage of the volume cannot be compensated as easily as when gas injection is used.


Training courses

14

Description:

Our courses and training programmes are always adapted specifically to the participants requirements (company course). According to our motto „From idea to series production“ in plastics technology we are able to establish a training concept that meets your needs.

Your advantage: • close to practice • with reference to your project(s) • individual

Physics of polymers Recognising part defects

Project training for design engineers e.g. design of feed gate

e.g. temperature regulation

Design with regard to injection moulding e.g. product development taking into account plastics and tooling issues

Examples:

Mould filling analyses/ distortion calculation

Simulation including temperature regulation

Cost-efficiency from product development to the injection moulding machine

Training location:

Over the last few years we often held trainings at our customers’ premises as it is sometimes easier to include current projects and difficulties into the training process. Alternatively, our training centre is a ten-minute walk from Neustadt train station. After an intense day of courses, the recreational values of nearby lake Steinhuder Meer and its surroundings invite you to relax. A comfortable hotel is waiting for you to rest in order that you can enjoy a fresh start to the following day of training.


Your problem is our job

15

Description:

Sink mark

We interpret defects (here: sink

marks) in the customer’s workpiece

and work on constructive solutions to

eliminate them.

Example:

Air trap

Injection moulding simulations ensure that there are no problems with ventilation or we work out new solutions for ventilation together with our customer.

Examples:

Vacuole in part reinforced with glass fibresl

When the part fails (void) we use fem analysis and injection moulding simulation to develop constructive modifications of the part and otimisations of the tool (e.g. for the gate) that ensure that the part meets the requirements in the future. Make use of our possibilities for solving your problems.

Part failure

12-15 expert lectures

50-60 exhibitors

300 – 400 participants

More information, registration forms and

reports can be downloaded at: www.Kb-Hein.de

We are looking foward to your visit!

A place to present problems, discuss solutions, exchange knowledge, get into contact and find co-operations.

Product DevelopmentMould Design Injection Moulding

When: End of February / beg. of March (see www.Kb-Hein.de)

Where: Neustadt (near Hanover, Germany)

Technology Workshop for

our team / contact information - konstruktionsbüro hein · entire range of services, consulting...

Documents