The paperboard Testing-Machine
Transcription
The paperboard Testing-Machine
+ + The+++++ Paperboard Testing-Machine + Development Process Thomas Weyrauch Degree project in Solid Mechanics Second level, 30.0 HEC Stockholm, Sweden 2011 Abstract The design of a paperboard testing machine, developed in order to analyse the mechanical behaviour of paperboard during the combined of out-of-plane shear and compressive loading as in the deepdrawing process, is presented. The methodology to design a paperboard testing machine is discussed and the most appropriate concepts are compared and evaluated. The design process is presented in detail, and some pilot tests are performed to give an overview about the functionality of the manufactured prototype. Preface Fibrous materials such as paper and board gain more and more usage in the manufacturing industry. New applications by new technological developments such as in deep-drawing of paperboard allow this sector to grow steadily. With this new field of application the requirements on the material are also increasing during the manufacturing process. Therefore, knowledge of the properties and the behaviour of the material under process-like conditions are relevant production factors. In order to get this knowledge, a testing procedure should be developed, which is similar to the requirements in the manufacturing process. This report presented here was carried out between March 15th and September 15th of the year 2011 at KTH (Kungliga Tekniska högskolan) in Stockholm, Sweden. Stockholm, September 2011 Thomas Weyrauch Student TU-Dresden/Germany Supervising tutor: Prof. Sören Östlund Professor in Packaging Technology and Head of the Department of Solid Mechanics Kungliga Tekniska högskolan (KTH) Stockholm, Sweden Contents 1 Introduction ................................................................................................ 1-1 2 The general concept ................................................................................... 2-3 2.1 Requirement specification .................................................................................................... 2-3 2.2 Developed concepts .............................................................................................................. 2-4 2.2.1 First Concept ................................................................................................................ 2-4 2.2.2 Second concept ............................................................................................................. 2-6 2.2.3 The third concept .......................................................................................................... 2-6 2.3 3 Comparison of concepts - weighted scoring......................................................................... 2-8 The pressure unit ....................................................................................... 3-9 3.1 Requirement specification of the pressure unit .................................................................. 3-10 3.2 Assembly of the pressure unit ............................................................................................ 3-12 4 The tension unit ........................................................................................ 4-15 4.1 Requirement specification of the tension unit .................................................................... 4-15 4.2 The assembly of the tension unit ........................................................................................ 4-17 5 The structure and case unit ..................................................................... 5-20 5.1 Requirement specification of the structure and case unit ................................................... 5-20 5.2 The assembly of the structure unit...................................................................................... 5-20 5.3 Analysis of the threaded sleeve .......................................................................................... 5-21 5.4 Tolerance analysis .............................................................................................................. 5-24 5.5 Case .................................................................................................................................... 5-25 6 Heat transfer analysis .............................................................................. 6-26 6.1 Heat transfer analysis of the punch .................................................................................... 6-26 6.2 Heat transfer simulation of the anvil .................................................................................. 6-28 7 Final proposal ........................................................................................... 7-29 8 The control plan ....................................................................................... 8-31 9 Requirements for the measurement and evaluation system ................ 9-33 10 Pilot tests .............................................................................................. 10-35 10.1 Structure and description of the prototype ....................................................................... 10-35 10.2 Accomplishment of the experimental ............................................................................... 10-37 11 Conclusion ........................................................................................... 11-39 List of Figures ............................................................................................... 11-40 List of Tables ................................................................................................. 11-41 Appendix ....................................................................................................... 11-42 1 Introduction Paperboard is one of the most used materials in the packaging industry. The market competition for paper and board is continuously increasing, and the main competitor for paperboard packaging materials is synthetic plastics. The ability to manufacture 3D shaped packaging components from paperboard is of utmost importance for the success of renewable wood fibre based materials in this competition. Paper is a fibrous material that consists of self-binding cellulose fibres. Fibres from trees, grass and other plants are used to manufacture paper. The most common fibres are from trees. During manufacturing of paper and paperboard, a fibre suspension is sprayed from a nozzle onto a net, called wire. Some water is drained on the rapidly traversing wire. Shear forces in the area where the jet hits the wire and after the pressure section, results in that the fibres are more oriented in the paper machine direction than in the cross machine direction. After dewatering on the wire more water is removed from the paper web in the press section. In the last step the paper is dried in a heated dryer. The direction of the fibres and also the drying process contributes to the anisotropy of the mechanical properties of paper.1 Paper materials consist of three main directions: the machine direction (MD), the cross machine direction (CD) and the trough thickness direction (ZD). They can approximately be used as the principal directions of the paper material and therefore paper is often considered as an orthotropic material.2 To get more information about the requirements on paperboard for the deep-drawing process or the most efficient settings of the process parameters, it is necessary to analyse the mechanical behaviour of paperboard in advance. In previous investigations, tensile tests, compressive tests and shear tests were used to analyse the elastic-plastic out-of-plane behaviour of paperboard. Most of them are conducted in ZD. The out-of-plane elastic-plastic behaviour of paperboard under combined normal and shear loadings is reported by Stenberg.3 However, in such thesis, the influence of paperboard during a process of combined out-of-plane shear and pressure under varied temperature has not been addressed. Therefore, a paperboard testing machine should be designed and manufactured by considering the deep-drawing process and variable temperature control. 1 Das Papierbuch; J H Bos, Martin Staberoc;, ECA Pulp and Paper B.V.; Niederlande 1999 Paper, Structure and properties; J.A. Bristow, P. Kolseth; Marcel Dekker, Series/8, 1986 3 Niclas Stenberg; On the Out-of-Plane Mechanical Behaviour of Paper Materials, KTH Solid Mechanics, Stockholm 2002 2 Thomas Weyrauch Report PTM A1 The aim of this work is to determine a method for recording the properties of paperboard during a process of combined out-of-plane shear and pressure. This would enable a possible construction or design of a paperboard testing-machine suitable for deep-drawing applications. By using the principle of the draft, a prototype of a paperboard testing-machine it has been designed and tested. The first results have been recorded and analysed. The report is divided into three parts: Gathering the possibilities and create concepts Create a draft of a test machine/ show the process of development Manufacture a prototype and run pilot tests Thomas Weyrauch Report PTM A2 2 The general concept 2.1 Requirement specification The most common way to start a new development project, like a paperboard testing machine, is to create a list of requirements. This is a table that include the complete, systematic collection of all requirements and should help to partition the project, to show possible problems and boundary conditions and also important for defining the system boundaries. Table 2-1 includes the specification requirements to create an overall concept for the development of a paperboard testing machine. Table 2-1: Requirement specification of overall paperboard testing machine concept; F = fixed requirement; O = optional requirement Requirement specification of overall concept changes F/O F F O O F F requirements Structure system: Massive; robust High generation load No specific provisions The blank: length - between 50 – 100 mm breadth - between 10 – 50 mm thickness - depending on the material used Kinematics: Translation Forces Normal compressive force: up to 100kN Shear force (about 50kN; at a coefficient of friction µ=0,5) F O O Energy Electrical power supply Hydraulic system Pneumatic system F Product material The blank consists of paperboard with different compositions F F Signals Processing of measurements displacement/pressure/force temperature measurement On/off Operator station F F Reliability Emergency stop Protective housing around F 1.ed.: 24/03/11 paper:1 responsible Ergonomics Thomas Weyrauch Report PTM A3 F F Easy removal of each components Easy to operate Production F F Production expenditure as low as possible Use standard parts F Inspection Technical Inspection Agency, ASME, DIN, ISO, CE W Servicing Low-maintenance 2.2 Developed concepts This chapter describes the identified concepts that are intended to solve the problem. Three concepts were identified and characterized with respect to their advantages and disadvantages. A subsequent scoring and an explanation show the most appropriate solution. 2.2.1 First Concept The first concept is shown in Figure 2-1 should be able to mount in an existing tension/compression testing machine with only one degree of freedom (in the vertical direction). MD Figure 2-1: First Concept This concept envisages the use of a round test piece. Figure 2-2 shows the possible behaviour of the blank during the test and the parameters that can be recorded. Thomas Weyrauch Report PTM A4 results: Deformation in ZD; MD; CD = f(T;p;v;m) and their interact among each other (e.g. using visual-xsel) after duct before deform. ZD; MD; CD T;p;v;m Figure 2-2: Behaviour of the first concept during a test As shown in Figure 2-2, the concept is able to record the deformations in the ZD, MD and CD directions combined vary temperature, but it depends on very high developed equipment. The problem of this concept is that it is not possible to record the properties of paperboard during a process of combined shear and pressure; it will only give the influence of pressure. According, an in-plane load cannot be applied and thus the requirements in Table 2-1 are not fulfilled by this concept. Table 2-2 shows all the pros and cons of the first concept. Table 2-2: Pros and Cons of the first concept Pros Cons Record compression Record elastic-plastic deformations in Very large amount of specific sensors could be result in an expensive machine ZD, MD, CD Complex system of sensors and software Vary temperature of punch (T) No shear Vary pressure (p) Vary rate of loading (v) Vary moisture content of blank (m) Thomas Weyrauch Report PTM A5 2.2.2 Second concept The second concept that is shown in Figure 2-3 is based on a principle with two moving components, a vertical movement in form of a compression realized by a defined weight or varying pressure, and a horizontal movement in form of a tensile force. A F Fp Fµ punch ZD CD defined weight or pressure Fµ anvil kg Ft MD L blank blank B A fixed heated punch heated anvil Ft v s : movement v : velocity s shear stress traktion compression Figure 2-3: Second concept In this concept it is advisable to use a rectangular blank, so it is possible to cut the blank in relation to the direction of the fibres. Thus, the influence of the MD and CD can be analyzed. Furthermore, the concept is able to combine out-of-plane normal and shear loading, which is very important according to the requirements. The Table 2-3 shows the pros and cons of the second concept. Table 2-3: Pros and Cons of the second concept Pros Cons Vary stress using different weights/ pressures Record shear stress under compression low or negligible influence of in CD and MD (individually) friction Find a way to move the anvil with Combined out-of-plane and in-plane loading Vary temp. of punch/anvil (T) sensors and the electronic against Vary pressure (p); velocity (v), moisture the shear force, Ft Very stiff structure to protect the content of blank (m) 2.2.3 The third concept Thomas Weyrauch Report PTM A6 The third concept is shown in Figure 2-4 and it is inspired by the deep-drawing process, with focus on the area around the bending corner. For instance, such concept consists of a fixed heated punch with an interchangeable attachment and a linear unit with a heated anvil and the blank. In this case the blank should be also rectangular. fixed and heated „punch“ with interchangeable attachment bending, compression, shear w,v,a FR.2 FR.1 FN.1 R blank FN.2 w = movement v = velocity a = acceleration linear unit Figure 2-4: Third concept; FN.i = normal forces; FR.i = friction forces The principle of the third concept is similar to that of the deep-drawing process. The linear unit which holds the blank moves to the fixed punch, and thus the blank is subjected to bending, compression and shear. Hence, the third concept could be a good testing method for analysis of the influence of parameters, important for the deep-drawing process. Using varied geometries of punch and anvil, the influence of the surface appearance or the radii of the punch and linear unit can be analysed. Table 2-4 summarises the pros and cons of the third concept. Table 2-4: Pros and Cons of the third concept Pros Cons Interchangeable geometries Possible to analyze bending, compression and shear similar to the deep-drawing process Clearance between punch and anvil Velocity (v) Temperature (T) Possible to investigate Coulomb friction (µ=constant) Thomas Weyrauch Report PTM Does not really describe the relationship between pressure and shear stress in a simple way It might be difficult to install load cells, Complex design Probably complex calibration A7 2.3 Comparison of concepts - weighted scoring After an overview about the three concepts, it is important to know which of these concepts is the most appropriate. A well-established procedure is the weighted scoring. The following main criteria are provided with a "weight" number according to their importance. Then, the concepts are evaluated in these criteria, to get a score. This score points are multiplied with the maximum achievable “weight” number to a “total”. Finally, all “totals” are combined into a final result, see Table 2-5. Scoring according to VDI 22254: 0 - unsatisfactory 1 - still acceptable 2 - sufficient 3 - good 4 - very good Weight/significance: 1 - low 2 - important 3 - very import. Table 2-5: Variants comparison – weighted scoring Criteria Weight Modularity Complexity Usable results Costs Result Score = Weight * Points Concept 1 Score Total 2 3 3 2 2 1 1 1 4 3 3 2 12 Concept 2 Score Total 3 3 3 3 Concept 3 Score Total 6 9 9 6 30 3 2 3 2 9 6 9 4 28 The possible solutions, which are included in the scoring, satisfy the main requirements according to the list of requirements. Therefore, in Table 2-5 only important targets were formulated and evaluated. Consequently, it was possible to create a ranking to determine the most suitable concept. In this case, the second concept result the most useful, and it is subject of development in the next chapters. Both concepts 2 and 3 provide useful results for the paperboard characteristics analysis, but there are differences. Concept 3 is fast and simple to explore the behaviour of the paperboard during the deepdrawing process. Thus, it is possible to optimize the settings in relation to the used material. In the same way the current acceptation of Coulomb friction, during the deep-drawing process, can be reviewed and tested. In contrast to Concept 3, Concept 2 can be used to analyse the behaviour of the yield stress at different various pressures. The knowledge about the stress-strain in out-of plane shear at different pressure is not only applicable to the deep-drawing process, but it is also suitable for other areas of paperboard converting and end-use, like folding, creasing and calandering. For a better understanding of the testing machine, the following chapters are devoted into the main components (main assemblies) of the testing machine, and they are individually designed. In Figure 4 Design engineering methodic - Engineering design at optimum cost, VDI 2225, Germany, 1998 Thomas Weyrauch Report PTM A8 2-5 it is shown the macro-structure of the testing machine and in Fel! Hittar inte referenskälla. the preliminary operation flowchart. actuation unit vertical actuation unit inclusion and guidance unit Pressure unit Fp punch incl. & guid. unit w;v:a punch anvil anvil Ft Tension unit l. unit actuation unit horizontal linear unit x-axis base structures system case system Figure 2-5: Macro-structure of testing machine This structure enables the machine to record the stress-strain in out-of-plane shear at different pressure. The punch moves downwards and loads the blank with the desired pressure. At that pressure, the bottom unit begins to move and a shear stress is generated in the test piece. These sequences of motion of the working units are illustrated in Figure 2-6. Pressure force F[kN] t[s] Tension force F[kN] t[s] Figure 2-6: Preliminary operation flowchart 3 The pressure unit Thomas Weyrauch Report PTM A9 3.1 Requirement specification of the pressure unit The requirements of the pressure unit are listed in Table 3-1. Fixed and several optional requirements are shown. Table 3-1: Requirement specification of the pressure unit; F = fixed requirement; O = optional requirement 1.ed.:24/03/11 requirement specification of pressure unit changes F/O F F F F O O F F F F F F O O F F F F F O O O F F O Thomas Weyrauch requirements paper:1 responsible Motion: High precision; robust; slow drive Linear; vertical drive High force generating No restoring force Over-design to prevent overloading Use a gear Inclusion and guidance unit: Guidance and bearing of the punch Guidance must run absolutely linear with low backlash Robust, stiff and resistant to deformation Connected to the frame and perform the movement of the punch Force transmission to frame Centring function Inclusion of pressure sensor and connection cable Easy dismounting of each components, in particular pressure sensor for calibration Punch: Massive and stiff High evenness of contact surface Specific surface roughness Heated Hardened stainless steel Good heat distribution Production: The i. and g. unit produced as casted parts The i. and g. unit produced as welded construction The clearance between guidance and bearing should be as small as possible. Precision production of the punch through milling, grinding and polishing Electropolished Report PTM A10 The requirements listed in Table 3-1 were considered and several solutions were developed for the individual main assemblies (cf. Table 3-2). From these options, three concepts that proved to be suitable were developed. The best solution was determined by using a weighted scoring Table 3-3. Table 3-2: The three concepts of the pressure unit - Concept 1 - Concept 2 - Concept 3 Table 3-3: The pressure unit concept scoring Criteria Weight Concept 1 Points Score Concept 2 Points Score Concept 3 Points Score Continuous train movement 2 3 6 3 6 1 2 Realize a high pressure 3 3 9 3 9 2 6 Cost 2 1 2 2 4 3 6 Temperature distribution 2 2 4 3 6 1 2 Result Score = Weight * Points Thomas Weyrauch 21 Report PTM 25 16 A11 3.2 Assembly of the pressure unit Concept 2 fulfills all the requirements after the scoring, and it was designed as an assembly shown in Figure 3-1. This exploded view presents every part of the assembly. The movement and the required compressive force will be realized by a hydraulic cylinder (1). The reasons for using a hydraulic system are the special properties against the other systems (cf. Table 3-2). Such as: continuous velocity setting optimal creative adaptation to space requirements linear movement simple generation of high forces high power density high duration of life high positioning accuracy By considering the small distance of the vertical movement due to the fluidness small of paperboard, it is sufficient to use a short stroke cylinder. An estimate of the required force was given in the doctoral thesis of Stenberg 5 . The Assfalg B04.5 cylinder fulfills all these requirements. The data sheet of this product is provided in the Appendix 1 (Data Sheets pressure unit). In order to measure the force between the punch and the blank, it is necessary to install a load cell (2). This is an integrated tension and compression sensor from Lorenz Messtechnik GmbH. It is designed for a maximum force of 200 kN and has an accuracy of Figure 3-1: The pressure unit 0.1 %. The sensor was over-designed, because the ideal working range of the machine is not yet known. Such sensor should be determined by preliminary tests using a prototype. The load cell is very sensitive to lateral forces, therefore it is 1 2 3 4 5 6 hydraulic cylinder force sensor traverse clamping element punch unit plain bushes necessary (as a transverse force is developed by the horizontal "pulling" of the anvil) to design a protection against the lateral displacement. To solve this 5 Niclas Stenberg; On the Out-of-Plane Mechanical Behaviour of Paper Materials, KTH Solid Mech. 2002 Thomas Weyrauch Report PTM A12 problem, a traverse (3) was designed. This traverse includes the punch unit (5) and two plain bushes (6) for the guiding rods. Using four clamping elements (datasheet is shown in the Appendix 1) the stamp unit could be frictionally connected with the traverse. The punch unit is the main sub-assembly of these components. Therefore it is necessary to describe it in more detail. The unit is shown in Figure 3-2 and Figure 3-3, respectively. adapter crankpin screw punch Figure 3-2: Punch unit Figure 3-3: Explosion view of punch unit The punch unit consists of the punch, the adapter and two screws for fixation each other. The two side bevels of the punch were used to create a work surface. The resulting area is roughly equivalent to the dimensions of the test piece. Furthermore, the component has two through bore-holes, and they are used for the inclusion of heating elements. To justify the number of such holes and their arrangement, a heat transfer analysis was carried out as described in Chapter 6. A crankpin was constructed for centering and balancing the shear force. All the component drawings as well as the assembly drawings with parts list are given in Appendix 6. In order to prove, or at least to give an understanding for the choice of the dimensions, the deformation of the at maximum load assembly was simulated using the finite element method to control the displacements. While on one hand it is necessary to protect the sensor, on the other hand a large displacement could falsify the results (torque arise) or cause the calibration to be complex. Fp Fp Ft Figures 3-4 and 3-5: Displacement of the pressure unit at maximum load during a typical test. The maximum displacement was 52.6 µm. Figures 3-4 and Figure 3-5 show the results of the simulation. The following assumptions were made in the simulation. First of all it was necessary to know the magnitude of the forces expected during a Thomas Weyrauch Report PTM A13 typical test. With a maximum pressure force (Fp) of 100 kN and a coefficient of friction of 0,5 (µ… rough reference value, according to reference6), a maximum tensile force (Ft) of 50kN was calculated. In Figures 3-4 and Figure 3-5 an ideal case was considered. This means the punch is pressing and sliding on a planar plate, so no torque is incurred. In this setting the displacement was constant (with max. 53µm) over the entire punch. In reality it will not happen due to the compressible paperboard between the punch and the anvil. The result of the simulation without the planar plate boundary condition (i.e. the punch is pressing and sliding on a planar plate) is shown in Figure 3-6. Torque around the x-axis Figure 3-6: Displacement of the pressure unit without boundary conditions of the punch; the maximum displacement yielded 89.7 µm¨ Now the displacement is not constant and the traverse is subjected to a torque. In both settings the displacements are not very high, but given the use of test pieces with different thicknesses (mostly thin paperboard between 0.3 and 2 mm); it is currently not known if this effect will influence the measurements. To find out if this behavior is negligible, it is necessary to make some preliminary tests using a prototype and record the displacement of these components during the tests. A stability simulation was executed as well, but this requires no discussion as the material is very stiff and no dangerous points were discovered. As evidence the result is shown in Figure 3-7. The used values and boundary conditions were the same as in the simulation of the displacement. The maximum stress, 320 MPa is a considerable lower than the allowed yield stress of the material (AISI 01 with Figure 3-7: stability simulation of to pressure unit Rc0.2 = 1350 MPa). 6 Paper and paperboard packaging technology, M. J. Kirwan, Blackwell, Oxford UK 2005 Thomas Weyrauch Report PTM A14 4 The tension unit 4.1 Requirement specification of the tension unit The specification of requirements for the tension unit is listed in Table 4-1. It illustrates the fixed and also several optional requirements. Table 4-1: Requirement specification of the tension unit; F = fixed requirement; O = optional requirement 1.edition 24/03/11 Requirement specification of the tension unit changes F/O requirements F F F O O Motion: High precision; slow drive Linear; horizontal drive Inclusion of the tension sensor Using a gear Over dimensioning to prevent overloading F F F F F Linear unit x-axis Guidance and positioning of the anvil Guidance must run absolutely linear with high accuracy Robust and stiff Connected to the base and performs the movement of the anvil Generation of high force O F F F F F F O O O O F paper:2 responsible Easy removal of each components, in particular tension sensor for calibration Anvil: Massive and stiff High evenness of contact surface Contact surface must be absolutely parallel to the surface of the punch Specific surface roughness Heated Hardened stainless steel Good heat distribution Production: Linear unit as a purchased item Linear unit as a own manufacture Electro polished surface of the anvil Precision production of the anvil, through milling, grinding, polishing Thomas Weyrauch Report PTM A15 Table 4-2: The concepts of the tension unit - Concept 1 - Concept 2 - Concept 3 Table 4-3: The variant scoring of the three tension unit concepts Criteria Constant train movement Resistant to high pressures Influence of friction Temperature distribution Weight 2 3 3 2 Result Score = Weight * Points Concept 1 Points Score 3 3 1 2 6 9 3 4 22 Concept 2 Points Score 3 3 3 3 6 9 9 6 30 Concept 3 Points Score 1 2 3 1 2 6 9 2 19 Just as in the previous chapter, using a variety of solutions, three concepts, see Table 4-3, were conceived and compared with each other. The concept with the best result in the scoring, in this case Concept 2, was most appropriate for implementation of the requirements. The design of this concept will be described in the following sections. Thomas Weyrauch Report PTM A16 4.2 The assembly of the tension unit An assembly that was designed from Concept 2, as it fulfills all the requirements in the scoring, is shown in Figure 4-1. z y 9 x 7 4 1 6 8 5 3 2 Figure 4-1: Tension unit assembly 1 2 3 4 5 anvil unit roller bearing shaft bracket guide rod joint head 6 7 8 9 pull rod adapter pull rod slotted nut with washer force sensor The anvil unit (1) is the main sub-assembly of these components together with the opposite part of the punch unit. This unit consists of the anvil, the carriage, two plain bushes and two roller bearings (2). The anvil is fixed with four screws and is exchangeable so it is easy to use anvils with different surface roughness. It will therefore be possible to find out the influence of the surface roughness during for example the deep-drawing process. The bottom profile of the anvil (the “two offsets”) is used to unload the screws in relation to the tension force during the process. The carriage has the adapted negative and is connected with the roller bearings (2) as well (cf. Appendix 6). These bearings can absorb a maximum compressive force of 300 kN (one of them) and they possess a very low tolerance (the datasheet is shown in the Appendix 2). Another reason for using roller bearings and not journal bearings is illustrated in Figure 4-2 and Figure 4-3. Fp Fp Ff,P anvil Linear roller bearings Ft Ff Figure 4-2: Friction forces on the anvil unit Thomas Weyrauch Figure 4-3: Force flow through the anvil unit Report PTM A17 The friction forces can be describe with the equations: Ff , p paper Fp (1) Ff roller Fp (2) Fp – pressure <100 kN Ff – friction force between bearing and bottom Ff , p paper roller – friction force between anvil and paperboard – friction coefficient of paper typically 0.3-0.6 – friction coefficient of the roller bearing, typically 0.0025 Using the values (paper = 0.5; Fp = 100 kN) and a blank with surface dimension 30x80 mm (p = F/A = 100 kN/2400 mm2 = ~ 42 MPa) in the equations yield: Ff , p 50 kN Ff 0.25kN Ff , p Ff Here, the friction force between the bearings and the bottom is much smaller than the friction force between anvil and paperboard. Therefore it is possible to neglect the influence of the friction force between the bearings and the bottom. For the use of a sliding bearing, the friction coefficient (µ = 0.1) as well as the friction force between bearing and bottom surface is higher. In this case the influence of the bearing is considerable and not negligible. These bearings have no guidance and they are moving only on two hardened plates, which are inserted into the basic plate as illustrated in Chapter 5. For this reason it was necessary to design a guidance to align the assembly. The solution was to use a guide rod, which is able to prevent the rotation/movement in the z-direction (the vertical direction) and in the x-direction (the vertical to the guide rod). The location of the coordinates is shown in Figure 4-4. Figure 4-4: Location of the coordinates Thomas Weyrauch Report PTM A18 Hence, a precise guidance can be warranted. The disadvantage, or what should be respected, is the knowledge of the tolerances of the used parts. It is absolutely necessary that the entire pressure will be carried by the roller bearings; otherwise the system would be over-determined. Therefore it is important to pay attention to this precision during mounting of the assembly. The guide rod is supported by two shaft brackets (Schaeffler Group). All tolerances can be taken from the data sheets and drawings in Appendices 2 and 6. A tolerance analysis can be found in Chapter 5. Also an important fact to consider is the height of the deformation of the anvil unit during a test. To check this, a simulation of the deformation was made using the maximum allowable forces. Figure 4-5: Deformation of the anvil unit; in vertical direction Figure 4-6: Von-Mises effective stress in the anvil unit at maximum load In Figure 4-5 the deformation of the anvil unit at maximum load (100 kN) is shown. Assuming that the roller bearings are not deformable a maximum deformation of 17 µm was found indicating that it is insignificant since the tolerances of the parts are larger. The data for the roller bearings under load are not stated by the manufacturer. If no information is to be found it is also necessary to analyse this behaviour by preliminary tests. The simulation of the effective stress (von-Mises criterion) is shown in Figure 4-6 and it can be concluded that the used material AISI 01 is stiff enough. The next observation that can be made is that the flow of the stress is located around the centre hole. This behaviour is desirable, because no stresses and strains are requested at the hole; otherwise this can result in undesired deformations. At each of the right and left sides of the balance is one pin which is used as a coupling for the traction unit. The pin is associated with a joint head (5) and a pull rod (6). The pull rod adapter (7) connects the two pull rods to one. In the middle of the adapter a load cell is fixed, which is associated with a hydraulic cylinder. The sensor can record tensile as well as compressive forces; therefore it is possible to move this unit in both directions. The used sensor is the same as the sensor in the Pressure Unit. Thomas Weyrauch Report PTM A19 5 The structure and case unit 5.1 Requirement specification of the structure and case unit The specification of requirements of the structure- and case system unit is listed in Table 5-1. Same as in chapter 4 are shown the fixed and several optional requirements. Table 5-1: Requirement specification of structure- and case system; F = fixed requirement; O = optional requirement 1.edition 24/03/11 Requirement specification of structure- and case system changes F/O requirements F O Structure system: Massive; robust High force generating No or negligible deformation including the bottom section and guidance of the transom panel Top plate and basic plate have to be absolutely parallel Overdimensioning F F F O Case system Casing of the system Safety appliance Delimitation of the surroundings e.g. dust and dirt Easy removal of each components F F F O O F F paper:1 responsible Production: Structure system can product as welded construction Structure system consists of components which are bolted together Structure system consists of steel with a high stiffness Case system consists of bent sheet metal or some parts of Plexiglas 5.2 The assembly of the structure unit The structural unit was designed according to the requirements. In order to construct the structure it was not necessary to find out the best solution using a scoring procedure. Here, one reasonable and realizable solution is sufficient. According to the requirement, the top plate should be as parallel to the basic plate as possible. A welded structure therefore appears to be quite unfavourable. Through the effect of heat, during the welding process, the material will be deformed and the construction must be processed again in hindsight. This can be very complicated and particularly costly. Therefore it was Thomas Weyrauch Report PTM A20 decided to design a structural unit that consists of two parallel plates and pillars. The result is shown in Figure 5-1. 5 2 3 4 8 7 6 1 2 3 4 5 6 7 8 base plate top plate column support guide rod threaded sleeve spacer piece hardened plates support pieces for the pull rod adapter 1 Figure 5-1: The assembly of the structural unit The structural unit consists of two plates, the base plate (1) and the top plate (2). The base plate supports the anvil-unit and the top plate is holding the pressure unit. Both plates are connected to each other via columns (3), but also the guide rods (4) have a supporting task. The only difference is the polished surface, because of the function to guide the traverse. All the columns and guide rods are fixed with two threaded sleeves (5), one for the bottom and one for the top. Due to the high forces, that are created during testing a calculation of the stiffness of the sleeves was necessary in order to find out if the dimensions were sufficiently large. The detailed calculation is described in Section 5.3. The two components spacer piece (6) and hardened plate (7) are very important for the tension unit. They must be manufactured with high precision and exact tolerances since they are also important to guide the unit precisely. A detailed tolerance analysis is given in Section 5.4. The component (8) is the support piece for the pull rod adapter. The pull rod adapter has a base where it can slide on the top (cf. Appendix 6). It is possible to coat the surface with a plastic layer to reduce friction. The stiffness and deformation of the structural unit was also simulated. The unit was definitely stiff enough and the displacements are quite small. A detailed overview of the results of the simulations is given in Appendix 3. 5.3 Analysis of the threaded sleeve Thomas Weyrauch Report PTM A21 First of all it was useful to describe the structure of the assembly shown in Figure 5-2. The assembly consists of a threaded pipe with M60 inside and an outer diameter of 90 mm. Two opposite side are milled to a distance of 80 mm, which corresponds to a wrench dimension. In the upper part of the component there is a thin cut until the middle of the component and a hole for an M5 screw. Hence, the screw can be fixed against undesirable torque and cannot be loosen. The only unknown dimension is the length (or the height) of the threaded sleeve. This will be found out with the following calculation. Figure 5-2: Threaded sleeve Thread: M60x1.5 Calculation of the thread reach and Allowable shear stress of the bolt and screw nut (3) – factor of shear stress In this case (4) Because of the same material C45E it follows that . From this - tensile strength For C45E 1. Material factor of bolt and screw nut (5) because (6) This yields: Thomas Weyrauch Report PTM A22 2. Diameter of shearing-off DIN ISO 13 ( ) (7) - pitch - thread angle This yields: 3. Force at the breaking limit (8) - stress area [ ] 4. Thread reach (9) - thread reach - shear stress at 100kN ( Fmax - Oversized) It was selected: - surface of the sheared cylinder Safety factor: (10) (11) Based on this calculation it was possible to determine the dimensions of the nut. Because of the large safety factor (S) and the assumed force per nut (which was over-dimensioned using 100 kN), it was not necessary to make further calculations. Hence, errors can be excluded from the outset. Nevertheless, the nuts should be tightened during maintenance to prevent creep. The drawing of this component can be found in Appendix 6. Thomas Weyrauch Report PTM A23 5.4 Tolerance analysis In the tolerance analysis it was important to consider whether the guide rod has a support function. First of all it is interesting to determine the tolerance range of the centerline (guide rod). In Figure 5-3 the tolerance chain of every component that belongs to it is shown. All these values were collected from Appendices 2, 3 and 6 (datasheets and drawings) and were presented here in simplified form. The red dimensioning (upper, right corner) indicates the region in which the centerline varies. This tolerance range results from the possible maximum and minimum variations of the dimensions. Figure 5-3: Tolerance chain According to these tolerances and using the tolerances of the plain brushes and the guide rod, it is still a clearance fit that is large enough to absorb deformations of up to 9 µm (cf. Figure 5-4), so it is possible to use higher pressures than 100 kN. Figure 5-4: Tolerance between guide rod and slide bushes Subject to compliance with all the tolerances at manufacturing and the subsequent accurate mounting, the guide rod will not have a supporting function. If there are some deviations with respect to the mounting, the faulty components have to rework. Thomas Weyrauch Report PTM A24 5.5 Case The case-unit has the task to create a boundary between the machine and the environment, to have a closed system. It is intended primarily to protect the operator. This testing machine compresses a blank with high hydraulic power using two working units. It is of utmost importance that nobody is able to touch them or to come into contact with other dangerous components during the movements of these units. A case around the testing machine was proposed. Figure 5-5 shows the result. 1 3 1 Al-profile 2 door 3 inclosure 2 Figure 5-5: Case The structure of this unit consists of aluminum profiles. Two doors were created for positioning and removing of the blank. It is recommendable to use some sensors to check if the doors are closed during testing. These sensors should be included in the control system. In this way it is impossible to run a test with open doors. Plexiglas® is useful for optical view of the test and protects the heated units against unwanted air flows. Therefore, it would be possible to have a constant surface temperature. In the back part of the case the side parts are enclosure (enclosure of iron), but it is also possible to use Plexiglas® or another kind of material. When designing one should pay attention to a simple removal of the plates in the case of maintenance or repair. It is also important, that there is enough space to include cables and sensors. The design of this unit is only a suggestion and no drawings are available. The final design should be created when all details of the testing machine are known. Thomas Weyrauch Report PTM A25 6 Heat transfer analysis The testing machine contains two parts that can be heated. They are the punch in the pressure unit and the anvil in the tension unit. In this chapter a heat transfer simulation of the punch and the anvil to find out the numbers of heating elements, the necessary requirements and the best arrangement is described. For every simulation a power of 10 W/cm2 was used. The heat simulation was performed with the Thermal Analysis module of Pro Engineer Wildfire 57. 6.1 Heat transfer analysis of the punch First of all the punch was simulated with one heating element. This element has the same size as than the length of the hole, a diameter of 6.5 mm and is made of stainless steel (with the material number: 1.4541 from the company Hotset®). As boundary conditions a heat transmission coefficient (α) of 20 W/(m2K) was used. This equates to a transmission from steel to inactive air (no air movement) that is similar to a normal room. Figure 6-1 shows the result of the simulation. Figure 6-1: Heat transfer of the punch with one heat patron and without an isolation layer The highest temperature is on the work surface, but the allocation of the heat is not constant over the whole surface. There is a variation, ΔT, of up to 20 K and one of the requirements for this function is a constant allocation over the surface, otherwise it can falsify the results. The next step in order to solve this problem is to use two heating elements. But there is also another problem which is very important to consider. This refers to the temperature at the end of the adapter (the blue area in Figure 6-1), because it is between 99-110 ˚C and this is too high. At the end, the adapter is connected to the pressure sensor and this sensor is not resistant against such high temperature. The maximum 7 Pro Engineer Wildfire 5, Parametric Technology Corporation (PTC), 2011 Thomas Weyrauch Report PTM A26 temperature that is allowed is 75˚C. To solve these problems it was necessary to change some construction details and to find a way to minimize the heat transfer to the end of the adapter. First of all, a second borehole was added. Both boreholes were positioned, so that the distance to the middle of the punch and the distance to the boundary of the work surface were the same, and the boreholes were symmetrically positioned. Figure 6-2 show the results of the new heat transfer simulation. Now a constant heat allocation over the whole work surface was obtained, in this example a temperature of 140˚C. Simulations with less power have led to similar results. Airflow cooling Figure 6-2: Heat transfer of the punch using two heat patrons, an isolation layer and an airflow cooling To minimize the heat transmission to the adapter, an isolation layer may be helpful, but it is impossible to use any kind of layer. There are several requirements on the isolation layer; first of all the layer should have a low heat transfer coefficient (and a good heat resistance as well) so that heat transfer will be prevented. The next point is the stiffness. According to the high pressures of the test, the isolation layer must be very stiff, so that no deformation can arise and the test result, for example the measurement of the deformation of the test piece, should not be affected. Polyamide 6.6 (PA 6.6) satisfied all requirements and therefore an isolation layer of PA 6.6 with a thickness of 2 mm was integrated into the assembly. The first simulation with the new parameters shows a sharp fall of the temperature, but it was still close to the limit of the sensor. In this case cooling using airflow was simulated for the rear part of the adapter. A heat transmission coefficient of 120 W/(m2K) was use as a boundary condition, that is a strong flow moving orthogonal to the surface. The result is shown in Figure 6-2. The temperature in the end decreased to 44-50˚C. For example, a ventilation system with a flow rate of around 195 m3/h can be used. Thomas Weyrauch Report PTM A27 6.2 Heat transfer simulation of the anvil This analysis is similar to the simulation of the punch unit. Using two heating elements is also necessary to realize a constant heat allocation on the work surface. In Figure 6-3 the result of the anvil unit simulation is shown. The work surface has a constant temperature over the whole area. An isolation layer was integrated as well. In this case this layer is not mandatory; as the bearings are not sensitive to high temperatures, but when comparing Figure 6-3 and Figure 6-4, some differences can be find which advocate the application of an isolator. In Figure 6-4 a better allocation of the temperature on the surface than in Figure 6-3 can be seen. Figure 6-3: Heat transfer simulation of the anvil unit without an isolation layer Figure 6-4: Heat transfer simulation of the anvil unit using an isolation layer This is due to the isolation layer that blocks the heat distribution and accumulates the heat in the anvil to the center. This chapter has discussed the simulation of heat transfer in the punch and anvil units, respectively, using heating elements. According to these simulations, it was possible to find the best adjustments and numbers of heating elements that are necessary to get a constant heat allocation on the work surface. The advantages and necessities of using an isolation layer were also advised. The next step is to manufacture the components, to mount them and after that to operate in a real test. In order to find the real behaviour of the heating process, it is absolutely necessary to record some calibration curves, which show the correlation between the settings of the heating elements and the temperature on the work surface. The recommendation is to record more than five curves. In this way you can find out the accuracy of the system using a statistical method. The equipment for the heating system consist of: a) controllable power supply to regulate the heating elements, b) some thermocouples with amplifier and a reader for the process monitoring , c) and one or two calibrated temperature gauges for the calibration, for example with an Almemo® or an IR camera Thomas Weyrauch Report PTM A28 7 Final proposal Previously, the assemblies and their components were explained and characterized in relation to their function. In this chapter all previously mentioned components are summarized and their co-action explained. First of all, the interaction between the pressure and the tension unit will be shown (see Figure 7-1). All the important relations and dimensions are shown in this figure. Thus we obtain a first overview of the size of the system. F[kN] Pressure force z,v,a max. 100kN t[s] Tension force F[kN] t[s] x,v,a Figure 7-1: Coaction of the punch and anvil unit Figure 7-1 shows the operation flowchart as well. In this diagram you can see the motions of the assemblies in one pass. It starts with the heat up the system (the punch and the anvil) and after the achievement of the desired temperature it follows the down movement of the punch unit until it touches the working surface of the anvil. Thereafter the sample is put under pressure until the desired force is attained. Following this, the movement of the tension unit begins. After completion of this phase, both units will be unloaded and moved back to their original positions. The diagram shown is only for illustration of the motions and it equates not curves from the real tests. It can be assumed that the curve starts with a sharp increase and after reaching the flow stress it will decrease again. Preliminary tests and measurements are indispensable to record the real behavior. Furthermore, the best settings and parameters for the test can be found out. A control plan with a path-time diagram is shown and explained in Chapter 8. The complete structure of the paperboard testing machine is found in the following figures. Figure 7-2 shows the design and the adjustment of the three assemblies; the pressure unit, the tension unit and Thomas Weyrauch Report PTM A29 the structural unit. The drawing of the assembly with all dimensions and list of parts is provided in Appendix 6. The picture below was rendered to give a more realistic view. Figure 7-2: Paperboard Testing Machine without the case In Figure 7-3 the complete testing machine with the case is shown. The case unit is absolutely necessary to comply with security regulations. Figure 7-3: Paperboard Testing Machine with the case A proposal for the design of the base frame was not given in this work because the place of location is yet unknown. Thomas Weyrauch Report PTM A30 8 The control plan The control plan, see Figure 8-1, includes every step in one turn. It should help in getting an overview of the test experiment. start punch temperature is achieved anvil temperature is achieved fresh blank is available positioning of blank referencing system Z=Z0 X=X0 start-up punch reach the blank realize resistance realize resistance Fp=F2 pressing process pressure force reaches adjust to Fp=F3 Residence time is achieved Start movement tension cylinder XXmax constant velocity V(x)=Vset=const adjust to V(x)=Vset load relieving/return punch load relieving/return anvil Removal of the piece end Figure 8-1: Control plan Thomas Weyrauch Report PTM A31 Z [mm] 1 Z4 Z23 Z12 2 3 4 5 6 7 ΔZ=Z23-Z12 X [mm] t[s] Xmax X0 t[s] Figure 8-2: Operation flowchart as a matter of principle path-time function for the motion axes of punch and anvil The operation flow consists of the following steps: 1 Move punch until touching the blank, the anvil unit is restricted from moving 2 At this region load until an adjusted force, so that the blank will be subjected to a prescribed compressive force; it is necessary and useful, to find out the point where the deformation will start; ∆z should be as small as possible 3 Deformation of the blank until the desired pressure is reached 4 Residence time of temperature and high pressure; time for deformation of the test piece 5 Movement of the tension cylinder to xmax with a constant velocity; punch is holding the pressure 6 Unloading and return of the punch to the reference point; the anvil stays in place 7 Return of the anvil to the reference point Thomas Weyrauch Report PTM A32 9 Requirements for the measurement and evaluation system The measurable characteristic variables in the test during one load cycle for each axis of movement are the force, the displacement and the acceleration as well as the temperature of heated components. The measured value acquisition during the test is shown in Figure 9-1. heating-up measurement Tpunch; Tanvil movement tension cylinder measurement xcyl, vcyl(t); Ft(t) start-up punch deformation measurement measurement zpunch; vpunch; Fz2 zdef(t); Fz(t); vdef(t); tresidence return/ interpretation measurement z(z0); x(x0), ANALYSIS sample Figure 9-1: Measured variables inside the process The variables necessary for regulating the actuators, such as cylinder force and displacement must be recorded by pressure sensors in the hydraulic system or by displacement transducers. The accuracy of the displacement transducers should be at least 1 micron. The tensile force is a frictional force and Thomas Weyrauch Report PTM A33 depends on the roughness of the surfaces and the punch force. It provides information about the behavior of the sample during the process by changing various process parameters. Thus, it is possible to find the stress-strain in out-of-plan shear at different pressure. The friction coefficients should be determined using appropriate external test equipment. The acceleration force of the punch can be determined by the application of an acceleration sensor and knowledge of the punch-weight. The evaluation of the measured displacement, pressure and acceleration takes place via a measuring board in a PC. The signals from the transducers can be used to determine the velocity. The temperature of the working members, punch and anvil, during the process are produced by the heating elements, which can be controlled by integrated thermocouples. Additionally, it is necessary to measure the temperature of the working surfaces. The reasons for this are the distance from the heating elements to the work surfaces and losses in the heat transfer. Therefore calibration is essential. Using the measurement and evaluation system, the entire process can be controlled and all parameters measured. Hence, it should be possible to analyse the behaviour and the properties of the used paperboard blank. Thomas Weyrauch Report PTM A34 10 Pilot tests According to the proposal in the first part of this report, a prototype was designed. The main components, such as the punch and the anvil, were manufactured and mounted with other components into an existing tension/compression testing machine. This chapter shows some pre-adjustments in assembling of the prototype, accomplishment of preliminary experiments and a conclusion with possible foresight. 10.1 Structure and description of the prototype Figure 10-1 shows a model of the prototype as well as the functionality. The core of the prototype consists of the punch (1) and anvil unit (2). In order to reduce the heat transfer to the load cell (12) an isolation layer of cork is used. Preliminary heating tests have revealed that the isolation layer is not enough to reduce the temperature to a minimum. In consideration to protect the load cell and to hold the temperature constant so that the test results are unaffected, a cooling system (11) was installed. The cooling system was based on the principle of flowing water. All these components, in the order described in Figure 10-1, were attached on a beam (13) in the compression testing machine that provided the required pressure. 1 2 3 4 5 6 7 8 9 10 11 12 13 punch unit anvil unit support plate carriage guidance rail vertical adapter load cell horizontal actuator horizontal thrust piece block piece cooling system load cell vertical beam Figure 10-1: Prototype model The anvil unit (2) is mounted on a support plate (3) which includes the actuator (8) for the horizontal movement. Using a carriage (4) with a guidance rail (5) the system is able to move horizontally. The thrust piece (9) that is fixed with the actuator (8) is pressed during the movement of the actuator (8) against the punch unit (1) using a vertical adapter (6) that is installed on the support plate (3). The Thomas Weyrauch Report PTM A35 movement can be transmitted to the carriage (4). During testing the thrust piece is guided and supported by a block piece (10). Recording of the forces are realized via a load cell (7) between actuator (8) and vertical adapter (6). Since the anvil also is heated, a cooling system was created to stop the heat transfer. The cooling system consists of a Ø10 mm borehole that is located under the anvil and is used as a canal for flowing water. The finished prototype is shown in Figure 10-2. Due to validation and calibration of the individual sensors, the prototype could be used. Figure 10-2: Finished prototype mounted in the tension/compression testing machine Thomas Weyrauch Report PTM A36 10.2 Accomplishment of the experimental The prototype has been tested by considering 5 different blanks with fibres in the machine direction (MD) and 5 blank with fibres in the cross machine direction (CD). Since the flow rate does not have a control system, it has been fixed empirically based on the results of some preliminary tests, where a suitable constant velocity was used. Then, every blank was tested separately at the same speed, by using different compressive loads, and the transversal load was measured by varying the movement. All the tested pieces had a thickness of 0.63 mm and a surface area of 2400 mm². Finally, due to the limitation of the testing machine, the considered movement range was between 0.0 and 1.5 mm. The results of the pilot tests are shown in Figure 10-3 for the blanks with fibres in the machine direction, and in Figure 10-4 for the blanks with fibres in the cross machine direction. 24 8MPa_MD 17MPa_MD 20 25MPa_MD transverse load/ kN 33MPa_MD 42MPa_MD 16 12 8 4 0 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 movement/ mm Figure 10-3: Results of the preliminary tests by using 5 blanks with fibres in the machine direction (MD) As expected, higher compressive loads result to higher transverse loads. The peak present in all the figures could be interpreted either as the point where the transverse load is high enough to overcome static friction or the transition point from elastic to elastic-plastic material behaviour. After this peak, the transverse load increases continuously but with smaller variations. It is interesting to see how the measured transversal load is similar in both MD and CD as shown in detail in Figure 10-5 and Figure 10-6. All the results are given in Appendix 4. Thomas Weyrauch Report PTM A37 28 8MPa_CD 17MPa_CD 24 transverse load/ kN 25MPa_CD 20 33MPa_CD 42MPa_CD 16 12 8 4 0 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 movement/ mm Figure 10-4: Results of the preliminary tests using 5 blanks with fibres in the cross machine direction (CD) transverse load/ kN 21 33MPa_MD 18 33MPa_CD 15 12 9 6 3 0 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 movement/ mm Figure 10-5: Comparison between MD and CD using a compressive load of 33 MPa 27 42MPa_MD transverse load/ kN 24 42MPa_CD 21 18 15 12 9 6 3 0 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5 1,6 movement/ mm Figure 10-6: Comparison between MD and CD using a compressive load of 42 MPa Thomas Weyrauch Report PTM A38 11 Conclusion In this report, a methodology to design a paperboard testing machine has been discussed. Such a methodology is capable to record the properties of paperboard during combined out-of-plane shear and pressure loading. The methodology consists of three phases: the development of a concept, the design and the assembling of a prototype. For each component of the testing machine, typically three concepts were described and a comparison between them was provided. The choice of the concept to be designed and assembled was based on an average scoring. Finally, some pilot tests were performed to validate the effectiveness of the chosen concept. Since the discussed methodology has been validated only for some specific case, it is premature to provide a generalization of the concept. However, the provided results still give reasonable insight into the principles of the paperboard testing machine, and the obtained results meet the theoretical expectations. Thomas Weyrauch Report PTM A39 List of Figures Figure 2-1: First Concept ..................................................................................................................... 2-4 Figure 2-2: Behaviour of the first concept during a test ....................................................................... 2-5 Figure 2-3: Second concept .................................................................................................................. 2-6 Figure 2-4: Third concept; FN.i = normal forces; FR.i = friction forces ................................................. 2-7 Figure 2-5: Macro-structure of testing machine ................................................................................... 2-9 Figure 2-6: Preliminary operation flowchart ........................................................................................ 2-9 Figure 3-1: The pressure unit ............................................................................................................. 3-12 Figure 3-2: Punch unit ........................................................................................................................ 3-13 Figure 3-3: Explosion view of punch unit .......................................................................................... 3-13 Figures 3-4 and 3-5: Displacement of the pressure unit at maximum load during a typical test. The maximum displacement yielded 52.6 µm. ..................................................................... 3-13 Figure 3-6: Displacement of the pressure unit without boundary conditions of the punch; the maximum displacement yielded 89.7 µm¨ ..................................................................... 3-14 Figure 3-7: stability simulation of to pressure unit ............................................................................ 3-14 Figure 4-1: Tension unit assembly ..................................................................................................... 4-17 Figure 4-2: Friction forces on the anvil unit ....................................................................................... 4-17 Figure 4-3: Force flow through the anvil unit .................................................................................... 4-17 Figure 4-4: Location of the coordinates ............................................................................................. 4-18 Figure 4-5: Deformation of the anvil unit; in vertical direction ...................................................... 4-19 Figure 4-6: Von-Mises effective stress in the anvil unit at maximum load ..................................... 4-19 Figure 5-1: The assembly of the structural unit.................................................................................. 5-21 Figure 5-2: Threaded sleeve ............................................................................................................... 5-22 Figure 5-3: Tolerance chain ............................................................................................................... 5-24 Figure 5-4: Tolerance between guide rod and slide bushes................................................................ 5-24 Figure 5-5: Case ................................................................................................................................. 5-25 Figure 6-1: Heat transfer of the punch with one heat patron and without an isolation layer ............. 6-26 Figure 6-2: Heat transfer of the punch using two heat patrons, an isolation layer and an airflow cooling ........................................................................................................................... 6-27 Figure 6-3: Heat transfer simulation of the anvil unit without an isolation layer............................... 6-28 Figure 6-4: Heat transfer simulation of the anvil unit using an isolation layer .................................. 6-28 Figure 7-1: Coaction of the punch and anvil unit ............................................................................... 7-29 Figure 7-2: Paperboard Testing Machine without the case ................................................................ 7-30 Figure 7-3: Paperboard Testing Machine with the case ..................................................................... 7-30 Figure 8-1: Control plan ..................................................................................................................... 8-31 Figure 8-2: Operation flowchart as a matter of principle path-time function for the motion axes of punch and anvil .............................................................................................................. 8-32 Figure 9-1: Measured variables inside the process............................................................................. 9-33 Figure 10-1: Prototype model........................................................................................................... 10-35 Figure 10-2: Finished prototype ....................................................................................................... 10-36 Figure 10-3: Results of the preliminary tests by using 5 blanks with fibres in machine direction (MD) ..................................................................................................................................... 10-37 Figure 10-4: Results of the preliminary tests by using 5 blanks with fibres in cross direction (CD) ... 1038 Figure 10-5: Comparison between MD and CD using compressive load of 33 MPa ...................... 10-38 Figure 10-6: Comparison between MD and CD using compressive load of 42 MPa ...................... 10-38 Thomas Weyrauch Report PTM A40 List of Tables Table 2-1: Requirement specification of overall paperboard testing machine concept; F = fixed requirement; O = optional requirement .............................................................................. 2-3 Table 2-2: Pros and Cons of the first concept ...................................................................................... 2-5 Table 2-3: Pros and Cons of the second concept .................................................................................. 2-6 Table 2-4: Pros and Cons of the third concept ..................................................................................... 2-7 Table 2-5: Variants comparison – weighted scoring ............................................................................ 2-8 Table 3-1: Requirement specification of the pressure unit; F = fixed requirement; O = optional requirement....................................................................................................................... 3-10 Table 3-2: The three concepts of the pressure unit............................................................................. 3-11 Table 3-3: The pressure unit concept scoring..................................................................................... 3-11 Table 4-1: Requirement specification of the tension unit; F = fixed requirement; O = optional requirement....................................................................................................................... 4-15 Table 4-2: The concepts of the tension unit ....................................................................................... 4-16 Table 4-3: The variant scoring of the three tension unit concepts...................................................... 4-16 Table 5-1: Requirement specification of structure- and case system; F = fixed requirement; O = optional requirement......................................................................................................... 5-20 Thomas Weyrauch Report PTM A41 Appendix Appendix 1: The pressure unit Appendix 2: The tension unit Appendix 3: The case and structure unit Appendix 4: Pilot tests Appendix 5: Datasheets materials Appendix 6: Drawings Thomas Weyrauch Report PTM A42 Appendix Appendix 1: The pressure unit Thomas Weyrauch Report PTM A1 ! " # $% " # & '& & () " *+ + , -%"! & &" . " '& /0 " 1 0%% 0 " 0 $ -%"! " ( 2 ! 3& 3 4)" !5 0 1 0%% & " 6%& 2788 "8% "8"8$8"!8&98&9:2 %" *0% ;<= => ?@ @ @ =A & # #% *% +7 ;8@ 20% &% + /7 ,&% 7 .A > %)0 @ B > C B @ B% > *% +7 ;8 "D ? @ @= E0% " &% " " F "& +, % "& 0 4 0 2011-08-16 12:16 1 2011-08-16 12:16 2 JENS S. Spännelement - Serie CN 31 Exempel: För axeldiameter d = 50 mm Spännelement CN 31 50 x 57 - Låga moment - Små radiella mått - Ekonomiskt - Ej självcentrerande Dimensioner Överförbart Vridmoment Axialkraft M Fa Nm N Yttryck Axel Nav Ps Ph 2 N/mm N/mm2 Nödvändig SkruvSpännkraft N AVSTÅND R mm ANTAL SPÄNNELEMENT 1 2 3 4 MÅTT DISTANSRING Di1 Dy1 mm mm Vikt dxD mm L mm L1 10x13 12x15 13x16 14x18 15x19 3,7 3,7 3,7 5,3 5,3 4,5 4,5 4,5 6,3 6,3 8 12 14 22 27 1600 2000 2150 3300 3600 100 100 100 100 100 80 80 80 80 80 14600 16100 16300 26200 27100 2 2 2 3 3 2 2 2 4 4 3 3 3 5 5 3 3 3 6 6 10,1 12,1 13,1 14,1 15,1 12,9 14,9 15,9 17,9 18,9 0,002 0,002 0,002 0,005 0,005 16x20 17x21 18x22 19x24 20x25 5,3 5,3 5,3 5,3 5,3 6,3 6,3 6,3 6,3 6,3 30 35 38 43 47 3700 4100 4200 4500 4700 100 100 100 100 100 82 85 84 80 80 27400 28150 28650 33150 33500 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 17,1 17,1 18,1 19,2 20,2 20,9 20,9 21,9 23,8 24,8 0,006 0,006 0,008 0,008 0,010 22x26 24x28 25x30 28x32 30x35 5,3 5,3 5,3 5,3 5,3 6,3 6,3 6,3 6,3 6,3 58 70 75 90 105 5300 5800 6000 6600 7000 100 100 100 100 100 85 88 83 90 90 34500 35150 27200 38100 41200 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 22,2 24,2 25,2 28,2 30,2 25,8 27,8 29,8 31,8 34,8 0,010 0,010 0,010 0,010 0,010 32x36 35x40 38x44 40x45 42x48 5,3 6 6 6,6 6,6 6,3 7 7 8 8 120 165 195 240 260 7600 9400 10000 12000 12400 100 100 100 100 100 90 90 90 90 90 42910 53250 57250 68350 71350 4 4 4 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 7 7 32,2 35,2 38,2 40,2 42,2 35,8 39,8 43,8 44,8 47,8 0,015 0,020 0,020 0,025 0,040 45x52 48x55 50x57 55x62 60x68 8,6 8,6 8,6 8,6 10,4 10 10 10 10 12 360 450 480 580 850 16000 18800 19000 21000 28500 100 100 100 100 100 90 90 90 90 90 107500 110500 111500 119500 155700 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 7 7 7 7 7 45,2 48,2 50,2 55,2 60,2 51,8 54,8 56,8 61,8 67,8 0,043 0,045 0,050 0,060 0,074 65x73 70x79 75x84 80x91 85x96 10,4 12,2 12,2 15 15 12 14 14 17 17 970 1350 1540 2210 2410 30000 38500 41000 55000 56500 100 100 100 100 100 90 90 90 90 90 163800 204000 221000 291500 306500 4 4 4 4 4 5 5 5 6 6 6 6 6 7 7 7 7 7 8 8 65,2 70,2 75,2 80,3 85,3 72,8 78,8 83,7 90,7 95,7 0,080 0,110 0,120 0,190 0,200 90x101 95x106 100x114 110x124 120x134 15 15 18,7 18,7 18,7 17 17 21 21 21 2750 3070 4200 5200 6100 61000 64500 84500 94000 101000 100 100 100 100 100 90 90 90 88 89 321500 331600 447000 487500 512500 4 4 4 5 5 6 6 6 6 6 7 7 7 7 7 8 8 8 9 9 90,3 95,3 100,3 110,3 120,3 100,7 105,7 113,7 123,7 133,7 0,220 0,230 0,380 0,410 0,450 Kg Seriemontage av spännelement Monteras flera spännelement av serie CN31 efter varandra, ökar det överförda vridmomentet vid oförändrat yttryck. Om man sätter katalogvärdet M=100% för ett spännelement,så ökar detta värdet vid: R 2 spännelement till 150% 3 spännelement till 185% 4 spännelement till 200% av tabellvärdet Fler än 4 spännelement i serie är inte motiverat eftersom det öveförbara vridmomentet inte ökar. Tryckfläns Enkelt förband Fig. 1 Ändaxelmontage Fig. 2 Navmontage 11 JENS S. Spännelement Serie CN 31 SKRUVBERÄKNING Ftot = Total åtdragningskraft (N) Ftot = Förspänningskraften (Fv) multiplicerad med antalet skruvar Förspänningskraften (Fv) fastställs för varje enskild skruv enligt vidstående tabell efter kvalitetsklass och gänga. Exempel Ett förband skall överföra max 40 Nm. Axeln är ø 25mm. I tabellen på sidan 11 finner vid d x D 25 x 30 med ett överförbart vridmoment M=75Nm. Den nödvändiga skruvspännkraften är 27 200N. Ur skruvtabellen till höger väljer vi ex vis 3 st skruvar M6 kvalitetsklass 12,9 med åtdragningsmoment Ms=17Nm och förspänningskraft Fv 15010 N. Ftot = Fv x antalet skruvar. Ftot = 15010 x 3. Ftot= 45030 N. Spännkraften blir alltså större än 27 200N. FLÄNSBERÄKNING Flänsen överför skruvarnas spännkraft till spännelement/ elementen. Flänstjockleken (t) överslagsberäknas. MATERIAL OCH SKRUVKVALITET I JENS S. SPÄNNELEMENT Levereras med skruvkvalitet 12,9 som standard. Här nedan anges de viktigaste uppgifterna om skruvkvalitet och storlekar Gänga ÅTDRAGNINGSMOMENT STANDARDGÄNGA (Metrisk) Kvalitet 8,8 Kvalitet 10,9 Kvalitet 12,9 Sträckgräns 640 Nmm2 Sträckgräns 900 Nmm2 Sträckgräns 1080 Nmm2 Ms Fv Ms Fv Ms Fv M5 6 6280 8,8 8980 9,8 M6 10 9320 14 12460 17 10640 15010 M8 26 16380 34 22910 41 27470 M 10 49 25950 69 36300 83 43510 M 12 85 37870 188 53320 145 63370 M 14 134 51500 189 72839 230 86940 M 16 206 71760 294 101440 355 121150 M 18 294 86670 402 121890 485 145090 M 20 402 112320 574 158240 690 190120 Ms = Åtdragningsmomentet Nm vid μ = 0,12 Fv = Skruvens förspänningskfraft N Anmärkning: I tvivelaktiga fall rekommenderar vi att välja närmast högre skruvkvalitet. Åtdragningsmomentet kan då höjas med 10%. TOLERANSER FÖR AXELDIAMETER a) Skruvmontage i axeln: (se fig 1 sid 11) t = skruvdiametern x 1,3 (mm) t = 6 x 1,3 = 7,8 mm Välj t = 8 mm b) Skruvmontage i navet: (se fig 2 sid 8) t = skruvdiametern x 1,8(mm) t = 6 x 1,8 = 10,8 mm välj t = 11 mm. d mm Axel Hål till 38 över 38 h6 h8 H7 H8 MONTERING Jens S Spännelement monteras enligt följande: * Gör rent axel och nav - olja in dem lätt. Använd ej smörjmedel som innehåller Molybdendisulfid. * Sätt samman spännelement, axel och nav och rikta upp förbandet. * Skruvarna dras korsvis till erforderligt åtdragningmoment (Ms) uppnås. SPÄNNSKRUVARNAS HÅLCIRKELDIAMETER (Dhc) a) Skruvmontage i axeln Dhc = Di - skruvdiametern - 10 (mm) Di = spännelementets innerdiameter (mm) Dhc = 25 - 6 - 10 = 9 mm b) Skruvmontage i nav Dhc = Dy + skruvdiametern + 10 (mm) Dy = spännelementets ytterdiameter (mm) Dhc = 30 + 6 + 10 = 46 mm För serie CN 31 gäller dessutom följande: * Kontrollera att avståndet mellan tryckfläns och nav är lika runt om. Tryckflänsen får inte ligga an mot navet. * När axelhålet har ett fristick, måste där placeras en distandsring. DEMONTERING Serie CN 55, 210, 911, 912, 913 och CN 914 Skruvarna gängas ur några varv. Genom lätta slag på skruvhuvudet lossar den bakre tryckringen. Den främre tryckringen lossas genom att använda avdragarhålen som är placerade under de blanka skruvarna. Serie CN 25 och CN25C Lossa muttern några varv. Lösgör spännelementet med lätta slag mot muttern 12 JENS S. TRANSMISSIONER AB Koppargatan 9, Box 903, 601 19 NORRKÖPING Tel: 011-19 80 00, Fax 011-19 80 54 www.jens-s.se VÄST Energigatan 10B S-434 37 KUNGSBACKA Tel: 0300-178 10 Fax: 0300-178 12 SYD Brännerigatan 5 S-263 37 HÖGANÄS Tel: 042-13 81 70 Fax: 042-13 83 70 Stora Varvsgatan 1 211 19 MALMÖ Tel: 040- 93 95 70 Fax: 040- 93 95 72 ÖST NORR Kanalvägen 1 A S-194 61 UPPLANDS VÄSBY Tel: 08-754 93 00 Fax: 08-754 93 50 Regementsvägen 10 S-852 38 SUNDSVALL Tel: 060-56 68 07 Fax: 060-12 30 10 KÖPENHAMN OSLO HELSINGFORS Brogrenen 5 DK-2635 ISHÖJ Tel: +45 4373 8333 Fax: +45 4373 1911 Enebakkveien 117 N-0680 OSLO Tel: +47 23 06 04 00 Fax: +47 23 06 04 01 PI 95 (Puolarmetsänkuja 6D) FIN-02271 ESPOO Tel +358 9 867 6730 Fax +358 9 867 6731 always one step ahead Heizelemente für die Verpackungsindustrie Packende Verbindungen! always one step ahead Seit der Gründung 1973 entwickelt und fertigt hotset Heizelemente und befindet sich seitdem auf einem kontinuierlichen Expansionskurs. Konsequent orientiert an den Bedürfnissen der Kunden löst hotset Heizaufgaben für industrielle Anwendungen. Mit Produktionsstätten in Lüdenscheid und auf Malta bietet hotset ein hohes Maß an Fertigungs-Know-how und für die Zukunft weiteres Entwicklungspotenzial. Angefangen bei einem breiten Lagerprogramm über StandardHeizelemente bis hin zur kundenindividuellen Sonderkonstruktion: Mit hotrod Heizpatronen, hotspring Wendelrohrpatronen und ® ® weiteren innovativen Produkten wie z. B. hotflex oder hotslot ® ® sowie der Qualität des Kundenservice bietet hotset die passende Beheizungslösung oder schafft sie kundenindividuell! hotset stellt immer wieder seine Innovationskraft unter Beweis – wie in diesem Prospekt – um Heizelemente anzubieten, die qualitativ hochwertig, technisch ausgereift und für die unterschiedlichsten industriellen Anwendungen geeignet sind. In Deutschland und über 30 Ländern weltweit ist hotset für seine Kunden – getreu dem Slogan „always one step ahead“ – immer einen Schritt voraus. Motivierte und qualifizierte Mitarbeiter sorgen dafür, dass hotset auch weiterhin für Kundennähe, Innovationen, Kompetenz und Zuverlässigkeit steht. Sie werden es sehen und erleben – versprochen! 2 always one step ahead Inhalt Anwendungsbeispiele Gerade in der Verpackungsindustrie wird das Tempe- 2 hotset 3 Anwendungsbeispiele für den Einsatz von hotset-Heizelementen in der Verpackungsindustrie raturfenster zur thermischen Bearbeitung von Werkstoffen immer enger. Komplexe Verpackungsmaterialien erfordern eine gleichmäßige Temperaturführung auf einem exakten Temperaturniveau, damit eine 5 hotrod Heizpatronen (Typ HHP) gleich bleibend hohe Produktqualität gewährleistet 6 hotrod Heizpatronen (Typ LHT) hotset bietet zahlreiche Heizelemente, die speziell auf 7 hotrod Heizpatronen (Typ LHT) biegbar 8 hotrod (Typ HHP) Ex-Schutz 9 ® ist. ® ® ® hotspring Wendelrohrpatronen (Typ WRP) ® die Anforderungen der Verpackungsindustrie abgestimmt sind. Zum Beispiel hotrod Heizpatronen (Typ ® HHP) mit individueller Leistungsverteilung und integriertem Thermoelement zur Beheizung von Schweißbalken, oder formbare Konturenheizungen, bei denen durch einen speziellen Innenaufbau die unbeheizten Endzonen extrem kurz gehalten sind. Fast ausschließlich handelt es sich bei den im Ver- 10 hotflex Flexibler Rohrheizkörper 12 hotcontrol Temperaturregelgeräte satzbereich in ihren Parametern stark variieren. 13 hotcontrol Thermoelemente und Widerstandsfühler Sie sich bitte an die hotset-Fachberater, die sich un- ® ® ® packungsbereich eingesetzten Heizelementen um anwendungsspezifische Lösungen, die je nach Ein- Bezüglich Ihres konkreten Anwendungsfalles wenden ter anderem auf die Lösung von Heizaufgaben in der Verpackungsindustrie spezialisiert haben. 3 always one step ahead für den Einsatz von hotset-Heizelementen in der Verpackungsindustrie Temp. Lg hotrod® (Typ HHP) Beheizung von Siegelköpfen hotrod® (Typ HHP) Beheizung von Schweißbalken hotrod® (Typ HHP) Leistungsverteilung Temp. Lg hotrod® (Typ HHP) Beheizung von Schneidmessern hotspring® (Typ WRP) Beheizung von Siegelköpfen hotrod® (Typ HHP) Leistungsverteilung Kartonagen, Papier- oder Blister-Verpackungen werden verklebt. Für das Erwärmen und Auftragen der Klebstoffe werden Heizelemente verwendet. Beim Schneiden, Stanzen oder Verschweißen von Kunststofftüten (Gummibärchen, Chips, Bonbons, ...) finden Heizelemente in Schneidmessern oder Schweißlinealen ebenfalls ihre Anwendung. Darüber hinaus können Heizelemente auch bei der Lebensmittelverarbeitung überall dort zum Einsatz kommen, wo die entsprechende Temperatur benötigt wird. 4 4 always one step ahead Qualität, die es in sich hat! hotrod Heizpatronen (Typ HHP) ® Technische Daten ● ● ● Anwendungsspezifische Leistungsverteilungen, integrierte Thermoelemente, zahlreiche Anschlussausführungen und ein umfangreiches ● Zubehör ermöglichen die individuelle Anpassung der hotrod ● ® Heizpatronen auf nahezu jeden Einsatzbereich. ● In Zusammenarbeit mit den Kunden entwickelt hotset innovative ● Produkte. ● ● ● ● ● ● ● Bestellangaben ● hotrod (Typ HHP) ® Anwendung: .......................................... + Artikel-Nr. (falls bekannt): .................. + Ø: ...................................................... + Länge: ............................................... + Leistung: ........................................... + Spannung: ......................................... + Anschlusslänge: ................................ + Anschlussausführung: ....................... + Thermoelement: ................................ + Messpunkt: ....................................... + Stückzahl: ......................................... Profil Ø [mm] (für Lager-hotrod®): 6,5; 8,0; 10,0; 12,5; 16,0; 20,0 Profil Ø ["]: 1/4; 3/8; 1/2; 5/8; weitere auf Anfrage max. Gesamtlänge: Ø ≥ 6,0 mm (geschliffen) 1500 mm Ø ≥ 6,0 mm (ungeschliffen) 3000 mm Mantelmaterial: Edelstahl Heizelement-Manteltemperatur: max. 750 °C Heizleiterwerkstoff: NiCr 8020 Hochspannungsfestigkeit (kalt im gestreckten Zustand) bei Nennspannung ≤ 24 V: 500 V-AC bei Nennspannung > 24 V: 1500 V-AC Isolationswiderstand (kalt): ≥ 5 MΩ bei 500 V-DC max. Ableitstrom (kalt): ≤ 0,5 mA bei 253 V-AC Längentoleranz: ± 1,5 %, min. ± 1 mm Leistungstoleranz (kalt): ± 10 % Durchmessertoleranz: metrisch -0,02/-0,06 mm zöllisch ± 0,02 mm/± 0,8 mils max. Anschlussspannung: 480 V, bei Lager-hotrod® 230 V (Standard) Thermoelement: Fe-CuNi (Typ J, Standard), optional Fe-CuNi (Typ L) bis 300 °C Arbeitstemperatur, NiCr-Ni (Typ K) bis 750 °C Arbeitstemperatur, potentialfrei, Messpunkte: am Boden oder mittig Anschlussausführung: z. B. 1000 mm von innen herausgeführte glasseiden isolierte Ni-Leitungen starre Drähte 1000 mm PTFE-isolierte Ni-Leitung (mehrdrähtig) außen angeschlagen 1000 mm silikonisolierte Ni-Leitung (mehrdrähtig) außen angeschlagen 1000 mm glasseiden isolierte Ni-Leitung (mehrdrähtig) außen angeschlagen 1000 mm von innen herausgeführte PTFEisolierte Ni-Leitung (mehrdrähtig), PTFEStopfen, Leistungsverteilung, feuchtigkeitsgeschützte Ausführung Andere Abmessungen und Produktvarianten auf Anfrage. Irrtum und technische Änderungen vorbehalten. Lagerabmessungen für hotrod® entnehmen Sie bitte dem Prospekt Lagerprogramm. Bitte beachten Sie die Einbau- und Lagerungshinweise. Bezüglich einer UL/CSA-Zertifizierung sprechen Sie bitte mit unseren Fachberatern. 5 always one step ahead hotrod (Typ LHT) ® Technische Daten ● ● ● ● ● Spiralpatronen Verdichtete oder nichtverdichtete Spiralheizelemente kommen überall dort zum Einsatz, wo aufgrund der ● ● ● anwendungstechnischen Voraussetzungen eine Oberflächenbelastung von 10 W/cm2 ausreicht. In diesen Fällen ermöglichen die Spiralheizelemente durch ihren einfachen Aufbau eine kostengünstige Beheizung bei hoher Lebensdauer des Heizelements. ● Im Bereich der Sicherheitskleinspannung ist bei Spiralheizpatronen die Stromrückführung über den ● Heizelementemantel möglich, so dass mit einem Anschluss gearbeitet werden kann. Darüber hinaus ● können die Anschlüsse bei Spiralheizelementen an ● beiden Seiten angebracht werden. ● Typische Einsatzbereiche für Spiralheizelemente sind ● die Beheizung von Siegelwerkzeugen in der Verpackungsindustrie, das Schneiden von Kunst- ● Profil Ø [mm]: 6,5; 8,0; 10,0; 12,5; 16,0; 20,0, mit beidseitigem Anschluss bzw. Rückführung über Heizelementmantel (andere auf Anfrage) Lager Ø [mm]: 10,0; 12,5; 16,0; 20,0 max. Gesamtlänge: 3000 mm Mantelmaterial: Edelstahl Heizelement-Manteltemperatur: max. 750 °C max. Manteloberflächenbelastung: 10 W/cm2 Heizleiterwerkstoff: NiCr 8020 Hochspannungsfestigkeit (kalt im gestreckten Zustand) bei Nennspannung ≤ 24 V: 500 V-AC bei Nennspannung > 24 V: 1500 V-AC (nicht bei Rückführung über Heizelementmantel) Isolationswiderstand (kalt): ≥ 5 MΩ bei 500 V-DC max. Ableitstrom (kalt): ≤ 0,5 mA bei 253 V-AC Längentoleranz: ± 1,5 % Leistungstoleranz (kalt): ± 10 % Durchmessertoleranz: ± 0,1 mm max. Anschlussspannung: 480 V Anschlussausführung: 250 mm von innen herausgeführte glasseiden isolierte Ni-Leitung stofffolien oder Textilien insbesondere mit der Messerpatrone oder die Beheizung von medizinischen Bestellangaben Apparaten oder Analysegeräten. 6 hotrod (Typ LHT) ® Anwendung: .......................................... + Artikel-Nr. (falls bekannt): .................. + Ø: ...................................................... + Länge: ............................................... + Leistung: ........................................... + Spannung: ......................................... + Anschlusslänge: ................................ + Anschlussausführung: ....................... + Stückzahl: ......................................... hotrod Messerpatrone Ø 5 mm Mantelmaterial: Incoloy ® Andere Abmessungen und Produktvarianten auf Anfrage. Irrtum und technische Änderungen vorbehalten. Bitte beachten Sie die Einbau- und Lagerungshinweise. 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"# $% %& '( )* + ,' * -! .-& - + -! ) & "!/ 0 0* 1#& + &- .-&& ! 2 /344'''**4 **44 4&4545*6/ $- 78 89 :; <; = ;< 8> * && $%3 ,< , 8 && 9< && ? < && 1@ @ && $%3 74=A9 9 >B && ; "9B ,; @ && $%3 74=A9 , @>AB && ,@ 99A> && ,B && C <; && $%3 74=A9@ C9 B@ && C? :; && 2@ "9; -! - .+D >B;=<*< + A ' E/ - * 9 9:A@ && : ; && 9 && F -! +- $@ : && < && & 2011-08-16 10:47 A<@ " 1 2011-08-16 10:47 2 1 -107 D 5~12 5% 20~49 15% € Stückpreis 13~19 10% 100 150 50 200 300 400 500 600 3∙4∙5 18,87 18,87 25,20 27,72 32,26 35,36 40,25 51,63 63,87 90,58 - 11,31 11,81 16,64 17,07 17,43 18,29 22,04 24,48 29,16 34,71 44,64 31,90 35,00 38,38 44,93 51,12 64,30 79,56 113,04 - 19,80 20,31 20,81 21,82 26,57 29,74 35,43 42,48 55,01 - 41,98 48,32 56,74 64,73 76,90 95,19 135,36 - 24,99 25,42 31,11 39,96 41,76 49,90 64,88 - 800 1000 1200 - C 0.4 max. 1.0 max. 0.5 G 80,93 96,20 118,95 169,35 - 49,97 52,20 62,36 81,08 - ∙ 1500 PSSFJ EPSSFU PSFJ EPSFU Ausführung 6.3 0.4 0.4 Teilenummer Ausführung D 6 8 10 12 13 15 (D-Toleranz f8) 16 PSFG 18 PSSFG 20 25 30 35 40 50 3 4 5 6 8 10 12 13 15 ∙ 16 18 ∙ 20 25 30 35 40 50 3 4 5 6 8 ∙ 10 12 ∙ 13 15 ∙ 16 18 ∙ 20 25 30 35 40 50 D Teilenummer 2-C Ohne Oberflächenbehandlung max. 0.2 Min. L L51 L101 L151 L201 L301 L401 L501 L601 L801 L1001 L1201 ~ 1,59 2,38 3,17 3,96 5,98 7,20 6 1,23 1,80 2,45 3,03 4,61 5,55 6,84 8,14 8 1,23 1,88 2,45 3,10 4,76 5,62 7,13 8,50 10 1,30 1,95 2,60 3,24 4,90 5,91 7,35 8,79 12 1,44 2,09 2,81 3,53 5,26 6,27 7,92 9,44 13 1,44 2,24 2,96 3,60 5,48 6,48 8,14 9,72 SFJ 15 ∙ 16 1,52 2,31 2,96 3,75 5,62 6,77 8,36 10,01 ESFU 18 ∙ 20 1,59 2,38 3,17 3,96 5,98 7,20 8,93 10,73 25 1,95 2,96 4,04 4,97 7,49 9,08 11,38 13,54 30 2,24 3,46 4,54 5,69 8,57 10,23 12,82 15,41 35 2,74 4,25 5,55 6,99 10,52 12,60 15,77 18,94 40 3,32 5,12 6,84 8,50 12,75 15,34 19,16 23,04 50 - 6,84 9,08 11,38 17,00 20,31 25,42 30,60 3 2,09 3,24 4,25 5,33 8,00 9,65 4 ∙ 5 2,09 3,10 4,18 5,19 6,84 7,71 6 2,38 3,60 4,83 6,05 7,92 8,79 11,38 14,12 8 2,38 3,60 4,83 6,05 7,92 8,79 11,38 14,12 10 2,38 3,60 4,83 6,05 7,92 8,79 11,38 14,12 12 ∙ 13 3,03 4,47 6,05 7,49 9,87 10,95 14,33 17,72 SSFJ 15 ∙ 16 3,75 5,62 7,49 9,44 12,89 14,76 17,14 19,37 ESSFU 18 ∙ 20 4,25 6,20 8,36 10,44 14,19 16,06 18,65 21,24 25 4,61 7,06 9,44 11,74 16,42 19,01 22,04 25,06 30 5,26 8,07 10,73 13,40 18,72 21,60 24,99 28,30 35 5,98 9,15 12,17 15,27 21,32 24,77 31,11 37,44 40 8,57 13,18 17,50 21,89 28,01 30,75 38,60 46,37 50 - 17,57 23,48 29,31 38,60 43,13 54,08 64,95 EBei Toleranz D h5 wird dem obigen Preis 2,00 EUR hinzugerechnet. Ausführung ~ ~ Teilenummer Stückz. 1~4 Mengenrabatte € Stückpreis ~ - G -0.025 -0.064 -0.007 0 -0.020 -0.009 -0.009 0 -0.025 -0.011 € Stückpreis max. 1.0 max. 0.5 C -0.020 -0.053 -0.017 -0.008 -0.010 -0.028 -0.013 -0.035 - -0.016 -0.043 G0 -0.006 0.4 0.4 -0.005 0 -0.014 -0.006 -0.004 0 -0.012 -0.005 L 1mm-Schritte 20~ 600 20~ 800 20~ 800 20~1000 25~1000 25~1000 30~1200 30~1200 30~1200 35~1200 35~1500 35~1500 50~1500 65~1500 8 10 12 13 6.3 15 16 18 20 25 30 35 40 50 6 4 5 3 f8 Min. L L51 L101 L151 L201 L301 L401 L501 L601 L801 L1001 L1201 EAngefragte Mindestmenge für Wellen der Präzisionskategorie größer als 30mm Außen-Ø mit LTBCBeschichtung ist 50. L 1mm-Schritte 10~ 400 10~ 400 10~ 400 20~ 600 20~ 800 20~ 800 20~1000 25~1000 25~1000 30~1200 30~1200 30~1200 35~1200 35~1500 35~1500 50~1500 65~1500 QMengenrabatt (EAbgerundet auf einen Cent.) S.87 ~ Preis (D Toleranz h5) SFU SSFU PSFU PSSFU D 3 4 5 6 8 10 12 13 15 16 18 20 25 30 35 40 50 ~ (D≤30, L≤500) SFJ SSFJ PSFJ PSSFJ RSFJ (D Toleranz g6) Teilenummer Ausführung L 1.1191 1.4301 0.4 1.3505 PSFG PSSFG 1,59 1,52 1,52 1,52 1,59 1,66 1,73 1,80 1,88 2,02 2,38 2,74 3,24 3,89 3,32 3,17 3,17 3,03 3,53 4,40 5,55 6,20 6,70 7,64 8,36 12,03 - 50 ~ - 1.4125 - - 2,38 2,16 2,16 2,31 2,31 2,38 2,67 2,67 2,74 2,96 3,75 4,25 4,97 6,05 8,00 4,97 4,68 4,68 4,61 5,26 6,63 8,28 9,22 10,23 11,81 12,89 18,51 24,92 3,17 2,96 2,96 3,03 3,17 3,24 3,53 3,60 3,68 3,89 4,97 5,62 6,63 8,00 10,66 6,70 6,20 6,20 6,20 6,99 8,79 11,09 12,24 13,76 15,77 17,21 24,77 33,20 100 150 ~ EEigenschaften von LTBC W S.118 EFür Rundheit und Geradheit D P.103 ~ hartverchromt Oberflächenhärte: HV750~ Beschichtungsdicke min. 5μm LTBC hartverchromt Oberflächenhärte: HV750~ Beschichtungsdicke min. 10μm. ~ 1.3505 3,96 3,60 3,60 3,82 3,89 4,04 4,40 4,47 4,61 4,90 6,20 7,06 8,21 10,01 13,25 8,36 7,85 7,85 7,64 8,79 11,02 13,83 15,34 17,21 19,66 21,53 30,89 41,48 200 ~ - ~ - 5,98 5,48 5,69 5,62 5,84 6,12 6,56 6,77 6,92 7,35 9,36 10,66 12,32 14,98 19,88 12,53 11,74 10,66 10,16 11,52 14,48 19,01 20,81 24,05 27,51 30,24 39,68 54,72 300 ~ - ~ induktionsgehärtet Effektive Einhärtetiefe DS.104 1.3505 58HRC~ 1.4125 56HRC~ 7,13 6,56 7,06 6,77 6,99 7,35 7,85 8,07 8,28 8,79 11,24 12,68 14,69 18,00 23,84 14,98 14,04 12,03 11,38 12,89 16,06 21,75 23,69 27,72 31,76 35,14 43,49 61,20 400 ~ 1.3505 1.4125 11,96 16,85 21,03 25,06 27,44 32,33 36,65 44,07 54,65 76,61 - 8,50 8,79 9,08 9,72 10,08 10,30 11,09 13,97 15,92 18,44 22,47 29,88 - 500 ~ - ~ D-Toleranz g6 h5 -0.002 0 -0.008 -0.004 12,53 20,74 26,00 28,52 31,18 36,87 41,62 53,00 65,74 92,02 - 10,16 10,59 10,80 11,67 12,03 12,39 13,32 16,71 19,08 22,18 26,93 35,93 - 600 ~ SFU SSFU PSFU PSSFU ~ D D 27,65 37,08 40,68 47,38 51,84 59,12 73,23 90,58 128,38 - 13,97 14,55 20,52 21,10 21,60 22,68 27,29 30,32 34,20 40,61 52,42 - 46,88 51,41 56,38 65,88 75,03 91,08 112,76 160,20 - 24,41 25,06 25,78 27,00 32,84 36,80 41,69 49,90 64,52 - 61,71 71,00 83,24 95,04 108,94 134,93 191,88 - 30,96 31,47 38,60 49,47 52,35 58,54 76,18 - 118,88 136,23 168,63 239,91 - 61,85 65,52 73,16 95,12 - 800 1000 1200 1500 ~ SFJ SSFJ PSFJ PSSFJ RSFJ ~ S Oberflächenbehandlung WSC A A WFC FC ℓ1 X E W Lieferzeit 8,28 7,71 7,78 7,85 8,86 9,00 9,94 9,94 10,88 13,18 14,84 17,86 13,61 15,63 17,50 20,60 21,68 25,28 27,00 30,96 31,25 42,05 48,60 W 5 7 8 10 11 13 14 16 17 22 27 30 36 41 Arbeitstage Arbeitstage 13 Arbeitstage - RSFJ WFC L 75 4,00 Stellschrauben-Planflächen an zwei Positionen hinzufügen Bestellnummer WFC10-A8-E20 WFC, A und E in 1mm-Schritten wählbar E WFC≤3xD D H E Wenn 1.5xD<FC, 2WFC≤L/2 3~ 5 0.5 E A (E) = 0 oder A (E) ≥ 2 6~18 1 Kann nicht auf der gleichen Ebene bearbeitet werden. 20~40 2 X 3 Kann nicht zusammen mit FC eingesetzt werden. 50 8,00 4,00 2,00 20 15 10 8 ℓ1 4,00 Aufpreis 6 8 10 12 13 15 ∙ 16 18 ∙ 20 25 30 35 40 50 6 8 10 12 13 15 ∙ 16 18 ∙ 20 25 30 35 40 50 1,44 1,52 1,52 1,66 1,66 1,73 1,88 2,31 2,67 3,24 3,96 5,26 3,39 3,39 3,39 4,25 4,25 5,26 5,84 6,56 7,49 8,50 12,24 16,49 100 4,76 4,90 5,04 5,48 5,55 5,76 6,20 7,85 8,86 10,80 13,18 17,50 8,86 9,08 9,08 11,38 11,38 15,27 16,64 19,66 22,40 25,64 31,83 44,72 2,38 2,45 2,52 2,67 2,81 2,96 3,10 3,82 4,40 5,48 6,63 8,79 5,55 5,55 5,55 6,99 6,99 8,79 9,72 10,88 12,53 14,19 20,45 27,36 7,13 7,35 7,56 8,14 8,43 8,57 9,22 11,67 13,25 16,28 19,80 26,28 14,33 14,62 14,62 18,36 18,36 20,16 21,96 26,00 29,38 38,81 48,10 67,32 1000 1500 1200 L801 L1001 L1201 CAD-Daten G WVC VC b1 h Y h Verfügbar nur für D = 12, 16, 20, 25 oder 30. Anwendungshinweise Eine Keilnut wird hinzugefügt. Bestellnr. KC10-G10 Zwei Keilnuten. Bestellnr. WVC180-F8 Anwendungshinweise Nur verfügbar für D = 6 und darüber XKann nicht mit VC verwendet werden WVC KC Fügt an einer Position eine V-Nut hinzu Bestellnr. VC8 Anwendungshinweise Nur verfügbar für D = 6 und darüber XKann nicht mit WVC verwendet werden 2x90° Planflächen für Stellschraube Bestellnr. WRC10-Y10 Anwendungshinweise Geeignet für D=10 ~ 30 XNicht in Verbindung C XNicht verfügbar auf derselben Ebene. Position Bestellnr. RC10 Anwendungshinweise Geeignet für D=10 ~ 30 XKann nicht mit WRC verwendet werden 90 Grad hinzufügen Stellschrauben-Planfläche an einer Anwendungshinweise XNicht anwendbar für RSFJ, PSFG und PSSFG sind nicht anwendbar. Änderung auf Außen-Ø h5 Toleranz Bestellnr. DKC Spez. VC WRC RC DKC Opt.-Nr. Straight Shaft Beispiel ESiehe Übersicht zu den Optionen, falls sie angegeben sind.D S.105 EBei mehr als einer Option ist ein Abstand von mindestens 2mm zwischen den bearbeiteten Bereichen erforderlich.D S.106 EOptionen können die Härte vermindern.D S.104 F b1 RC b1 Optionen 5,00 4,00 2,00 10,00 5,00 - Optionen-DetailsD S.105 Aufpreis 9,80 10,16 14,33 17,07 14,62 17,50 15,05 17,86 21,53 15,77 18,80 21,89 19,01 22,97 26,79 21,10 25,64 34,42 43,06 25,06 30,60 36,00 45,00 29,88 36,65 42,99 53,72 38,52 47,38 55,88 69,84 19,59 19,59 26,14 33,05 26,14 33,05 28,80 36,29 43,49 33,41 39,82 50,12 36,65 46,52 58,76 41,76 53,00 67,11 83,96 53,50 66,60 79,71 99,72 66,32 82,52 98,72 123,41 93,89 117,22 140,33 175,54 800 L601 200 600 400 ~ € Stückpreis L401 L201 Min. L L101 ~ DKC Optionen wurden im Juni 2010 eingestellt. (RSFJ muss am 13. Tag Bitte neue Teilenummern angeben; SFU, SSFU, PSFU und PSSFU auf der nach Bestellung versendet linken Seite, um Bestellungen aufzugeben. werden) KC WRC 10 Arbeitstage PSSFG PSFG FC 8,00 EUR/ Express A Einheit EExpressgebühr von 21,60 EUR für 3 oder mehr identische Artikel. 5 D 6 8 10 12 13 15 16 18 20 25 30 35 40 50 Schlüssel-Planflächen an zwei Positionen hinzufügen Bestellnummer WSC12-X8 Anwendungshinweise Nur verfügbar für D = 6 und darüber. WSC/X in 1mm-Schritten auswählen. E WSC+X+ℓ1x2<L E WSC (X)=0 oder WSC (X)≥1 E Kann nicht auf der gleichen Ebene bearbeitet werden. Nicht in Verbindung mit SC verwenden. Fügt einen Satz Schlüsselflächen hinzu. Bestellnummer SC5 Anwendungshinweise Nur verfügbar für D = 6 und darüber SC=1mm-Schritte E SC+ℓ1≤L E SC=0 oder SC≥1 X Kann nicht mit WSC verwendet werden Entfettungs-Service DS.83 8 Spez. 13,11 12,32 13,25 15,20 17,28 18,36 21,17 22,90 25,85 29,24 36,44 41,40 Toleranzänderungen Maß L (Präzisionsausführung) Bestellnummer LKC Bei Verwendung von LKC können die L-Maße in 0.1mm-Schritten gewählt werden. E L<200 CL±0.03 200≤L<500CL±0.05 L≥500 CL±0.1 LKC 11,88 10,52 11,52 13,40 14,55 15,63 17,50 19,16 21,24 23,76 29,09 37,37 D Teilenummer Ausführung Stellschrauben-Planfläche an einer Position hinzufügen Bestellnummer FC10-A8 FC und A wählbar in 1mm-Schritten. D H 3~ 5 0.5 E FC≤3xD 6~18 1 E Wenn 1.5xD<FC, FC≤L/2 20~40 2 E A=0 oder A ≥ 2 3 XKann nicht mit WFC verwendet werden 50 WSC SC LKC Opt.-Nr. 9,87 8,93 9,87 10,01 12,03 12,10 13,90 13,90 20,88 19,80 23,62 26,57 (LKC/SC...etc.) 9,08 8,36 8,36 9,36 11,31 10,59 11,45 12,24 13,32 17,57 19,30 23,98 Teilenummer - L - 250 SFJ30 7,49 7,13 7,13 7,20 7,35 7,35 8,28 8,28 8,36 10,23 10,44 12,39 50 500 100 ~ 400 ~ 300 L101 ~ 200 L151 ~ 150 L201 ~ Bestell- Teilenummer SFJ20 beispiel WFC ℓ1 ℓ1 LKC Optionen W RSFJ SC 3∙4∙5 6 8 10 12 13 15 16 18 20 25 30 Optionen D Ausführung L401 L301 ~ L51 ~ € Stückpreis ~ Min. L ~ Teilenummer DKC H Härte ~ h h Ausführung M D Toleranz g6 D Toleranz h5 D-Toleranz f8 Werkstoff ~ ~ EWellenlänge kann in 1mm-Schritten ausgewählt werden. ~ ~ -Gerade Ausführung- h h ~ Weitere Details siehe Optionen-Übersicht D S.105 Wellen h ~ 1 -108 Appendix Appendix 3: The case and structure unit Thomas Weyrauch Report PTM A3 Appendix Thomas Weyrauch Report PTM A4 Appendix Appendix 4: Pilot tests Thomas Weyrauch Report PTM A5 ) ) ) * * * + + + ) ) ) * * * + + + ) ) ) ) ) ) ) ) ) ) ) ) !" #!"$%! & ##"%#$'( $('"$ '$!' !"!&$ without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ *12 / 13 $.($"$!'/ transverse load/ kN "! $#!(*12 ) * + movement/ mm without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ )12 / 13 $.($"$!'/ * "! $#!()1213 ) * + without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ 12 / 13 $.($"$!'/ * "! $#!(1213 ) * + without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ * 12 13 $.($"$!'/ "! $#!(1213 ) * + without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ 12 / 13 $.($"$!'/ "! $#!(13 ) * + ! " without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ *12 / 13 $.($"$!'/ "! $#!(*123 ) * + # without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ )12 / 13 $.($"$!'/ * "! $#!()123 ) * + ## $ without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ 12 / 13 $.($"$!'/ * "! $#!(123 * ) * + #% without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ * 12 13 $.($"$!'/ "! $#!(123 ) * + #& without heat "!'' #!,! &!$#&'#!( $-! &.#'/ 0*0 "! $#!(/ 12 / 13 $.($"$!'/ "! $#!(123 ) * + '() *12413 )12413 12413 12413 * 12413 ) * + '*() * *1243 )1243 1243 1243 * 1243 ) * + 1353$'6 ! *12 *12413 *1243 ) * + 1353$'6 ! )12 * )12413 )1243 ) * + 1353$'6 ! 12 * 12413 * 1243 ) * + 1353$'6 ! 12 12413 1243 ) * + 1353$'6 ! 12 12413 1243 ) * + Appendix Appendix 5: Datasheets materials Thomas Weyrauch Report PTM A6 Auer Kunststofftechnik GmbH & Co. KG Werkstoffdatenblatt Polyamid 66 HI Chemische Bezeichnung: DIN-Kurzzeichen: Farbe, Zusätze: PA 6.6 HI Polyamid 66 PA 66 braun, Hitzestabilisator Hauptmerkmale sehr fest steif gute Gleit-/Reibeigenschaften stabilisiert gegen Wärmealterung hohe Zähigkeit beständig gegen viele Öle, Fette und Kraftstoffe gut zerspanbar verschleißfest gut elektrisch isolierend gut schweiß- und klebbar Anwendungen Maschinenbau Automobilindustrie Transport- und Fördertechnik Elektrotechnik Feinwerktechnik Haushaltsgeräte Textilverarbeitung Beispiele div. Maschinenteile, Zahnräder, Gleitlager, Gleitleisten, Buchsen, Nockenscheiben, Seilrollen, Laufrollen, Führungselemente, Steckverbindungen Mühlbachstraße 1, 74078 Heilbronn Telefon 07131/59438-0 Telefax 07131/59438-20 www.auer-kunststofftechnik.de E-Mail: [email protected] Auer Kunststofftechnik GmbH & Co. KG Werkstoffdatenblatt Polyamid 66 HI (PA 6.6 HI) Eigenschaften Mechanisch trocken / feucht Streckspannung 80 / 60 MPa DIN EN ISO 527 Streckdehnung 4 % DIN EN ISO 527 Reißfestigkeit Norm MPa Reißdehnung 50 / 150 % DIN 53 455 Zug-E-Modul 2700 / 1600 MPa DIN EN ISO 527 Biege-E-Modul MPa Härte 170 / 100 Schlagzähigkeit 23º C n.b. Zeitstandfestigkeit DIN 53 456 (Kugeldruckhärte) kJ/m² DIN EN ISO 179 (Charpy) MPa nach 1000 h bei stat. Belastung Zeitdehnspannung 6 MPa für 1% Dehnung nach 1000 h Gleitreibungskoeffizient p = 0,05 N/mm²v=0,6 m/s gegen Stahl gehärtet und geschliffen Gleitreibungsverschleiß µm/km p = 0,05 N/mm²v=0,6 m/s gegen Stahl gehärtet und geschliffen trocken / feucht Thermisch Kristallitschmelzpunkt Norm °C Glasübergangstemperatur 72 / 5 °C DIN 53 765 Formbeständigkeitstemperatur 100 °C ISO-R 75 Verfahren A (DIN 53 461) 200 °C ISO-R 75 Verfahren B (DIN 53 461) kurzzeitig 180 °C dauernd 115 °C Wärmeleitzahl (23º C) 0,23 W/(K·m) Spez. Wärmekapazität (23º C) 1,7 J/g.K lin. therm. Längenausd.koeff. (23-55º C) 8 10 1/K HDT, Verfahren A Formbeständigkeitstemperatur HDT, Verfahren B Maximale Anwendungstemperatur -5 DIN 53 752 Mühlbachstraße 1, 74078 Heilbronn Telefon 07131/59438-0 Telefax 07131/59438-20 www.auer-kunststofftechnik.de E-Mail: [email protected] Auer Kunststofftechnik GmbH & Co. KG Werkstoffdatenblatt Polyamid 66 HI (PA 6.6 HI) Elektrisch trocken / feucht Norm Dielektrizitätszahl (106 Hz) 3,2-5 DIN 53 483, IEC-250 Dielekt. Verlustfaktor (106 Hz) 0,025-0,2 DIN 53 483, IEC-250 Spezifischer Durchgangswiderstand 10^12 Oberflächenwiderstand 10^10 Durchschlagsfestigkeit 100 / 80 Kriechstromfestigkeit KB>600 KC>600 *cm DIN IEC 60093 DIN IEC 60093 kV/mm DIN 53 481, IEC-243, VDE 0303 Teil 2 DIN 53 480, VDE 0303 Teil 1 Sonstige trocken / feucht Dichte 1,14 g/cm Feuchtigkeitsaufnahme 2,8 % DIN EN ISO 62 Wasseraufnahme bis zur Sättigung 8,5 % DIN EN ISO 62 Brennbarkeit nach UL- Standard 94 HB Norm 3 DIN 53 479 im NK bis zur Sättigung (1) Geprüft an gepressten Platten (2) Geprüft an Halbzeug (3) Literatur Wert Unsere Informationen und Angaben entsprechen dem heutigen Stand unserer Kenntnisse und sollen über unsere Produkte und deren Anwendungsmöglichkeiten informieren. Sie haben somit nicht die Bedeutung, die chemische Beständigkeit, die Beschaffenheit der Produkte und die Handelsfähigkeit rechtlich verbindlich zuzusichern oder zu garantieren. Unsere Produkte sind nicht für eine Verwendung in medizinischen oder zahnmedizinischen Implantaten bestimmt. Etwa bestehende gewerbliche Schutzrechte sind zu berücksichtigen. Sofern nicht anders vermerkt, wurden die Werte an spritzgegossenen Prüfkörpern in "spritzfrischem" Zustand ermittelt. Technische Änderungen vorbehalten. Mühlbachstraße 1, 74078 Heilbronn Telefon 07131/59438-0 Telefax 07131/59438-20 www.auer-kunststofftechnik.de E-Mail: [email protected] F A K TA OM VERKTYGSSTÅL ARNE Kallarbetsstål Där verktyg tillverkas Där verktyg används ARNE Uppgifterna i denna trycksak bygger på vårt nuvarande kunnande och är avsedda att ge allmän information om våra produkter och deras användningsområden. De får således inte anses utgöra någon garanti för att de beskrivna produkterna har vissa egenskaper eller är lämpliga för speciella ändamål. 2 ARNE Egenskaper Allmänt ARNE är ett oljehärdande mangan-, krom- och volframlegerat verktygsstål av universaltyp med stor användbarhet för kallarbetsändamål. Dess viktigaste egenskaper är: • God skärbarhet • God måttbeständighet vid härdning • En bra kombination av hög ythårdhet och seghet efter härdning och anlöpning. Tillsammans ger dessa egenskaper ett stål som lämpar sig för tillverkning av verktyg med god livslängd och tillverkningsekonomi. ARNE levereras i olika utföranden, däribland varmvalsat, förbearbetat, finbearbetat och precisionsslipat. Det kan också erhållas i form av hålad stång. Riktanalys % Standard C 0,95 Mn 1,1 Cr 0,6 W 0,6 V 0,1 FYSIKALISKA DATA Härdat och anlöpt till hårdhet 62 HRC. Data vid rumstemperatur och förhöjd temperatur. Temperatur 20°C 200°C 400°C Densitet kg/m3 7 800 7 750 7 700 190 000 19 500 185 000 19 000 170 000 17 500 Elasticitetsmodul N/mm2 kp/mm2 Längdutvidgningskoefficient per °C from 20°C – Värmeledningsförmåga W/m °C 32 33 33 34 34 Specifikt värme J/kg C 460 – – 11,7 x 10-6 11,4 x 10-6 (SS 2140), AISI O1, W.-Nr. 1.2510 Leveranstillstånd Mjukglödgat till ca. 190 HB Färgmärkning Gul TRYCKHÅLLFASTHET Ungefärliga värden. Användningsområden Verktyg för Klippning Stansning, hålning, snoppning, klippning, skäggning Materialtjocklek upp till 3 mm 3–6 mm 6–10 mm Stukgräns Rc0,2, N/mm2 62 HRC 60 HRC 55 HRC 50 HRC 2200 2150 1800 1350 HRC 60–62 56–60 54–56 Kortslagssaxar för kallklippning Skäggningsverktyg för smidda ämnen Hårdhet 54–60 varmt kallt 58–60 56–58 Formning Bockning, dragpressning, kantvalsning, trycksvarvning och sträckpressning 56–62 Små präglingsverktyg 56–60 Mätverktyg Svarvdubbar Styrhylsor, utstötarpinnar Små kugghjul, kolvar, munstycken, kammar Maskinkomponenter utsatta för slitage 58–62 Skäggnings- och kantformningsverktyg i verktygsstål ARNE för behållare av 0,91 mm tjock rostfri stålplåt, i dimension 254 x 152 x 203 mm. 3 ARNE Värmebehandling ANLÖPNING MJUKGLÖDGNING Skydda stålet mot ytavkolning och genomvärm till 780°C. Därefter svalning i ugn med 15°C per timme till 650°C och sedan fritt i luft. AVSPÄNNINGSGLÖDGNING Välj anlöpningstemperatur enligt diagrammet för att erhålla avsedd hårdhet. Anlöp två gånger med mellanliggande kylning till rumstemperatur. Lägsta anlöpningstemperatur 180°C. Hålltid vid anlöpningstemperatur min 2 timmar. Anlöpningsdiagram Efter grovbearbetning bör verktyget genomvärmas till 650°C. Hålltid 2 timmar. Långsam svalning i ugn till 500°C, därefter fritt i luft. Hårdhet, RC Restaustenit % 66 64 HÄRDNING 62 Förvärmningstemperatur: 600–700°C Austenitiseringstemperatur: 790–850°C Austenitiseringstemperatur 60 820°C 58 Temperatur °C Hålltid* minuter Hårdhet före anlöpning 56 800 825 850 30 20 15 ca. 65 HRC ca. 65 HRC ca. 63 HRC 52 54 790°C 50 48 * Med hålltid avses tid vid austenitiseringstemperatur sedan arbetsstycket är helt genomvärmt. 14 Restaustenit 850°C 46 12 44 Skydda detaljen mot avkolning och oxidation under värmning för härdning. 10 8 42 40 38 6 4 36 2 100 SLÄCKNINGSMEDEL • Olja • Etappbad, 180–225°C, därefter kylning i luft. Notera: Anlöp så snart arbetsstycket nått en temperatur av 50–70°C. 8 66 6 64 4 62 2 60 40 30 760 780 20 10 800 820 840 860 Austenitiseringstemperatur 4 500 600 700°C Verktyg vid austenitiseringstemperatur nedsänkes i etapphärdningsbadet under tid enligt tabellen och kyles därefter i luft till en temperatur av 50–70°C. Anlöp omedelbart som vid oljehärdning. Hålltid 1tim. Restaustenit 400 ETAPPHÄRDNING Restaustenit % Hålltid 20 minuter 300 Anlöpningstemperatur Hårdheten som funktion av austenitiseringstemperaturen. Kornstorlek Hårdhet ASTM HRC 10 Kornstorlek 200 880 °C Austenitiseringstemperatur °C Temperatur på etappbad °C 825 825 825 850 225 200 180 225 Ythårdhet före Hålltid i anlöpning etappbad, (erhållen vid minuter etapphärdning) max. 5 max. 10 max. 20 max. 10 64±2 HRC 63±2 HRC 62±2 HRC 62±2 HRC ARNE DJUPKYLNING OCH ÅLDRING DIMENSIONSÄNDRINGAR VID HÄRDNING Provplatta 100 x 100 x 25 mm Oljehärdning från 830°C min. max. Bredd % +0,03 +0,10 Etapphärdning från 830°C min. max. +0,04 +0,12 Längd % +0,04 +0,10 Tjocklek % – +0,02 +0,06 +0,12 – +0,02 DIMENSIONSFÖRÄNDRINGAR VID ANLÖPNING Detaljer som kräver maximal måttstabilitet bör djupkylas och/eller åldras för att volymändringar inte skall uppstå med tiden. Detta gäller exempelvis mätverktyg och vissa konstruktionsdetaljer. Djupkylning Omedelbart efter släckningen bör arbetsstycket djupkylas till mellan –70 och –80°C, hålltid 3–4 timmar, med efterföljande anlöpning eller åldring. Djupkylning ökar hårdheten med –3 HRC. På grund av sprickrisken bör komplicerad utformning undvikas. Åldring Anlöpning efter släckning ersättes med åldring vid 110–l40°C. Hålltid 25–100 timmar. Dimensionsförändring % +0,1 0 –0,1 –0,2 100 200 300 400°C Anlöpningstemperatur Notera: Dimensionsförändringarna vid härdning och anlöpning skall adderas. Rekommenderad arbetsmån 0,25%. Stansverktyg av finbearbetat verktygsstål ARNE. 5 ARNE Skärdatarekommendationer BORRNING Snabbstålsborr Nedanstående skärdata är att betrakta som riktvärden, vilka måste anpassas till rådande lokala förutsättningar. SVARVNING Borrdiameter Ø mm Skärhastighet (vc) m/min. Matning (f) mm/varv –5 5–10 10–15 15–20 16* 16* 16* 16* 0,08–0,20 0,20–0,30 0,30–0,35 0,35–0,40 * För belagd snabbstålsborr vc = 22 m/min. Svarvning med hårdmetall Skärdataparameter Grovsvarvning Finsvarvning Svarvning med snabbstål Finsvarvning Skärhastighet (vc) m/min. 140–170 170–220 20 Matning (f) mm/varv 0,3–0,6 –0,3 –0,3 Skärdjup (ap) mm 2–6 HårdmetalIbeteckning ISO –2 –2 P20–P30 P10 Skärdataparameter Typav avborr borr Typ Solid hårdmetallborr Lödd hårdmetallborr1) Skärhastighet (vc) m/min. 120–160 60 55 Matning (f) mm/varv 0,05–0,252) 0,10–0,252) 0,15–0,252) Belagd hårdmetall Belagd hårdmetall eller cermet 2) Fräsning med hårdmetall GrovFinfräsning fräsning Borr med invändiga kylkanaler och lödda hårdmetallskär. Beroende på borrdiameter. SLIPNING Fräsning med snabbstål Finfräsning Nedan ges en mycket allmän slipskiverekommendation. För mera detaljerade sliprekommendationer hänvisas till broschyren ”Slipning av verktygsstål”. Slipskiverekommendation Mjukglödgat Härdat tillstånd tillstånd Skärhastighet (vc) m/min. 160–200 200–240 25 Typ av slipoperation Matning (fz) mm/tand 0,2–0,4 0,1–0,2 0,1 Planslipning rak skiva –2 Planslipning segment A 24 G V A 36 G V Rundslipning A 46 L V A 60 J V Innerslipning A 46 J V A 60 I V Profilslipning A 100 L V A 120 J V Skärdjup (ap) mm HårdmetalIbeteckning ISO 2–5 –2 P20–P40 P10–P20 Belagd hårdmetall Belagd hårdmetall eller cermet — Pinnfräsning Typ av fräs Skärdataparameter Solid hårdmetall Hårdmetallvändskär Snabbstål 50 120–170 251) Matning (fz) mm/tand 0,03–0,22) 0,08–0,22) 0,05–0,352) HårdmetalIbeteckning ISO K20, P40 P20–P30 — Skärhastighet (vc) m/min. 6 Korthålsborr — Plan- och hörnfräsning 2) Skärdataparameter 1) FRÄSNING 1) Hårdmetallborr För belagd snabbstålsfräs vc = 35 m/min. Beroende på radiellt skärdjup och fräsdiameter. A 46 H V A 46 G V ARNE Svetsning Gnistbearbetning Svetsning av verktygsstål kan genomföras med gott resultat om hänsyn tas till förhöjd arbetstemperatur, fogberedning, elektrodval och stränguppbyggnad. Verktyg, som skall poleras eller fotoetsas, måste svetsas med artegna elektroder. Om gnistbearbetning utföres på verktyg i härdat och anlöpt tillstånd, bör en extra anlöpning ske vid en temperatur som ligger ca 25°C under föregående anlöpningstemperatur. Svetsmetod Arbetstemperatur Tillsatsmaterial Hårdhet efter svetsning Metallbågsvetsning MMA 200–250°C AWS E312 ESAB OK 84.52 UTP 67S Castolin 2 Castolin N 102 300 HB 53–54 HRC 55–58 HRC 54–60 HRC 54–60 HRC AWS ER312 UTPA 67S UTPA 73G2 Castotig 5 300 HB 55–58 HRC 53–56 HRC 60–64 HRC Gasvolframsvetsning TIG 200–250°C Ytterligare information Kontakta närmaste Uddeholmskontor för ytterligare information om val, värmebehandling, användningsändamål, leveransformer och utföranden av Uddeholms verktygsstål samt broschyren ”Stål för klipp- och pressverktyg”. Jämförelsetabell för Uddeholms kallarbetsstål MATERIALEGENSKAPER OCH MOTSTÅND MOT SKADEMEKANISMER Uddeholm Hårdhet MaskinbearbetMåttbebarhet Slipbarhet ständighet Abrasiv nötning Adhesiv nötning Urflisning/ Brott Plastisk deformation ARNE CALMAX RIGOR SVERKER 21 SVERKER 3 VANADIS 4 VANADIS 10 VANADIS 23 7 Appendix Appendix 6: Drawings Thomas Weyrauch Report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