PRODUCTS
CONNECTORS FOR CLUTCH LINE SYSTEM
For clutch line systems of the polyamide 12 Vestamid, which
have shown good performance for years, Degussa AG in Düsseldorf has developed,
together with customers, compatible polyamide 12 connectors that can be directly
injection moulded to the line. A clutch line system consisting wholly of Vestamid
offers a high safety standard and affords price and weight advantages as compared
with ordinary metal systems and plastic lines with metal connectors.
The system consists of a mono-tube of Vestamid L2141 with connectors of 30%
fiberglass-reinforced Vestamid injection moulded onto it. The use of the same
material base provides an intimate joint between the line and the connectors.
This provides reliable resistance to pressure and leakage to meet the demands
of the automotive industry. The recommended compounds are particularly resistant
to motor oil, aggressive chemicals and, of course, the hydraulic fluids used.
Because of its good heat aging resistance, the line system can be used at
elevated temperatures in the engine compartment. In addition, the water absorption
of the line through diffusion is very low, so the function of the hydraulic
fluid is not impaired.
www.degussa-hpp.com
This clutch line system, consisting wholly of polyamide
12 Vestamid, reduces weight and costs as compared
with metal or plastic/metal systems (photo: Degussa)
Lightweight speaker grills
The automotive industry is a key sector for the HTP High Tech
Plastics AG from Neudörfl/ Austria, and they are focusing on cost and
weight savings. For example, a major area for HTP is the production of speaker
grills. Using state of the art injection moulding, it is possible to make
precision grilles featuring a variety of different designs. The company believes
that this not only yields weight savings but also delivers financial benefits
since plastic speaker grills are much cheaper than their metal equivalents.
Other products made by HTP include ventilator grills, A, B and C column covers,
and cabin safety fittings, where heat-resistant plastics are combined with
other materials such as metals.
HTP makes all its own moulds to handle processes such as textile backing spraying,
gas-filled internal pressure injection moulding, and multi-component injection
moulding. Over the past few years, HTP High Tech Plastics AG has established
business relations with various multinational companies in the automotive,
aviation and electronic industries.
www.htp.at
AUTOMOTIVE PAINT – finding the right formula
The array of paint colours available on the market poses special
problems in the car repair sector. Paints have to be specially ordered. To
tackle the problem DuPont Performance Coatings (DPC) have been using Cognos
Impromptu to analyse the mixing formulae for various shades of automotive
refinish paint. The resulting colour information system details the composition
of all colours developed by DPC. The company claims that this makes final
paint selection speedier and more accurate, since customers can now order
the exact shade required.
Jochen Harz and Heidrun Samsz, of DPC quality control, are clear about the
benefits of the system. “Our colour database contains a lot of information.
What we needed was an analytical tool to enable us to identify which mixed
coating is used how often and in which formula”, explained Jochen Harz.
DuPont USA was already using the Cognos system, and a workshop was organised
in May 2001 to assess whether the system could be implemented in Germany.
“The results of the workshop were very positive, and potential users
were highly impressed by the user-friendliness of the program”, added
Harz. The Cognos Impromptu system is currently being tested, and it is hoped
that 20 DPC staff will shortly be using the client version of the software.
Ultimately, information about paint formulae will be accessed directly by
laboratories and also by “Colour Service Departments”, who advise
automotive coating and repair workshops.
www.performance-coatings.org
www.cognos.com
To navigate your way effectively around the world
of automotive paint all you need is the refinish
coatings colour database. (photo: Cognos)
Precision parts French style
Specialising in the manufacture of precision parts in all types
of thermoplastics for car interiors and exteriors, French company Adduxi,
Bellignat/France makes use of think3 3D software in its manufacturing programme,
allowing input of 2D spatial, wiring and planar models from .iges, .VDA, .DXF
and .STRL files or directly from Catia or Pro.E format. It offers additional
processes such as assembly and welding. The 58 strong company, which has subsidiaries
in Switzerland and Germany, has an extensive array of state of the art machines
and uses SPC in its quality control process.
www.adduxi.com
Higher Reactivity Flame Retardant for Foam Applications
Great Lakes Chemical Corporation introduced Firemaster 520,
a higher reactivity flame retardant for rigid polyurethane and polyisocyanurate
foam applications. The product was developed in close consultation with foam
manufacturers who need to change their formulations to accommodate alternative
blowing agents that are quickly replacing HCFC, which is subject to phase-out
under the Montreal protocol.
Firemaster 520, with its primary hydroxyl reactive groups, offers fast reaction
rates, low viscosity, and good compatibility in water blown foams. In many
applications, a higher reactivity flame retardant is preferred to reduce cycle
time and surface friability. The reduced surface friability helps to improve
the adhesion of facing sheets to the foam surface. In spray foam, a lower
viscosity, higher reactivity flame retardant is needed to prepare low viscosity,
fast curing spray foam systems.
The introduction of Firemaster 520 adds to Great Lakes’ range of bromine-,
phosphorus- and antimony-based flame retardants for the polyurethane industry.
These flame retardants, along with Great Lakes’ range of UV stabilizers,
antioxidants and stabilizer blends, are used in rigid and flexible foams,
elastomers and coatings.
www.greatlakes.com
VISUAL STEREO SOLUTIONS
3Dims is breaking new ground in terms of design with the latest
developments in semi-mobile VR solutions in their Buenavista range. These
have displays integrated into back projection boxes in such a way that the
visual coverage reaches the furthest possible horizontal limits. More of these
displays can therefore be horizontally clustered and used in a flexible way.
3Dims GmbH is a worldwide developer, distributor and installer of standard
high specification as well as individually customised and two-way compatible
VR systems and components, from small ultra-portable and cost-effective stereo
projection system through to multichannel VR solutions. 3Dims invented “portable
reality” (transportable stereo projection solutions) and is said to be
the first in the world to develop “Tri-space”, a three-way projection,
whose visualisation technology is based on circular polarised light.
www.3Dims.de
The 3Dims GmbH «portable reality» solution is equipped with
the Fujitsu-Siemens Computers Mobile H, the XPO2 stereo
converter and the 3Dims 3D stereo projection system. This
set offers a cost-effective introduction into 3D stereo projection.
ULTRASONIC MOULD CLEANING
KLN has developed special ultrasound cleaning systems for cleaning
moulds for many injection moulds require absolute cleanliness as part of their
care and maintenance routines for the manufacture of faultless product. The
new system features intensive sound transmission said to be able to clean
even hard-to-reach places to perfection. Ultrasonic cleaning involves generator-produced
electrical oscillations being converted by a sonic transducer into mechanical
vibrations. This produces cavitation on the contact surfaces of the object
being cleaned and in the cleaning medium, which works intensively to remove
clinging foreign bodies. The process is intensive but claims to be gentle.
KLN ultrasonic mould cleaning equipment offers effective anti-corrosion protection
and can leave the equipment dry until further use.
www.kln.de
Burnt rubber residues, oxides and parting
agents had to be removed from high precision
steel moulds.
Single cavity hot runner nozzles for rapid prototype production
Husky Injection Molding Systems has introduced a new product
line of simple hot nozzles, which are based on the manufacturer’s ultra
nozzle platform. The nozzles can be delivered within 24 hours ready to install
and use in moulds with thermal sprue or valve gating. The new single cavity
runners have been designed with prototypes or simple production line tools
in mind. The nozzle configuration and gate detail of the valve gate moulds
are identical with those of our reusable VG and VX nozzles and eliminate the
cold sprue, reducing resin consumption. The new single cavity nozzles can
be delivered as fully pre-assembled units and can on request be custom-fit
to special machine nozzles with client-specific gate diameter. The valve gate
nozzles are available in 10 different lengths and with nozzles in sizes 500
or 750 with VG valve gates for amorphous and VX valve gates for crystalline
and reinforced / filled plastics. The thermal sprue systems are ideally suited
to thermal gating and can be supplied in 10 different lengths with ultra nozzles
in sizes 250, 500 and 750 for all standard valve gates.
www.husky.ca
Optical Digitisation of Freeform Surfaces
The Comet VarioZoom is an optical digitising system for the
measurement of 3D coordinates. The system is based on whitelight fringe projection
or can be used with the laser-based, hand-held triangulation scanner Comet
T-Scan. The system is particularly suited for design and quality control applications.
The company Steinbichler from Neubeuern, Germany, claims that its new system
offers a significantly shorter measuring and post-processing time, thanks
to a variable field of view and the software controlled rotation table. No
photogrammetric measurement preparations are necessary. In design applications,
the Comet plus feature, the feature lines of the design are extracted from
the polygon mesh automatically and with high accuracy, which, according to
the company, represents an economic solution for the post processing of 3D
files. For quality control applications the company states that the digitised
data produced by Comet inspect can be compared with imported CAD data. Deviations
are then displayed numerically and graphically.
www.steinbichler.de
Hand-held triangulation scanner Comet T-Scan
Aluminium alloy tools and moulds
Almet amb, a subsidiary of Pechiney Rhenalu, developed a new
aluminium alloy, Alumold 1-500, which is claimed to have an almost constant
level of strength through to the plate core. Almet amb claims that cost savings
of between 20% to 40% can be achieved by substituting aluminium, a recyclable
material, for stainless steel in the manufacture of tools and moulds can be
significant especially when processing costs are high in relation to the materials
usage. Today, new processes cut down the time required between mould design
and production and the finished plastic component. The industry is increasingly
demanding the ability to manufacture metal prototypes, pre-production line
and production line moulds more quickly and at lower costs. HSC technology
can make a significant contribution to this, and is particularly suitable
for high strength aluminium, reducing the manufacturing time of the plastic
moulds and the production costs through lower cycle times for the manufacture
of plastic components.
www.almetamb.de
www.pechiney.com
Hybrid moulds for rapid processing
Together with the University of Clausthal, Eisenhuth Präzisionsformenbau,
Osterode/Germany has developed a new type of mould technology: the hybrid
mould. This consists of a combination of different mould manufacturing techniques.
It uses not only standard mould manufacturing technology but also laser sintering
techniques. Standard mould manufacturing technology can be used in less complex
areas. This includes milling, lathing, cavity sinking EDM, wire EDM and turning.
Areas that predominantly require delicate techniques use direct metal laser
sintering. Complicated electrodes can also be produced using this process.
Laser sintering components are used in this process, which are manufactured
in a direct metal laser sintering plant by the firm EOS (Electro Optical Systems),
including both steel components and bronze components, which can be 20m in
size. Eisenhuth claims to be able to achieve a reduction in the manufacture
of pre-production moulds of up to 50%.
www.eisenhuth.com
All-in-one moulds for part of a safety belt
system, which is extremely complex, except
for the outer contours
CENTRAL ARMREST AND REAR-VIEW MIRROR
The team at Proma ProjektManagement GmbH from Lichtenfels/Germany,
offers its considerable development expertise to design, and bring to the
production stage, a wide variety of products for the automotive industry and
for manufacturers of domestic appliances. Proma is presenting a complete seating
systems project from initial design stage through to the production line.
Electric headrests and a range of other technical features have been incorporated
into the central armrests. Another recent development is the exterior rear-view
mirror, bristling with technical refinements, of the Volkswagen Phaeton luxury
limousine.
www.proma-redwitz.de
Working prototype of adjustable
electric headrest and central armrest
(photo: Johnson Controls)
Conference on ‘Plastics in automobile construction”
On the 2nd and 3rd of April, the VDI Association for Plastics
Technology in Mannheim is to hold its international conference on “Plastics
in automobile construction”, incorporating a special exhibition on “Elastomers
in the automobile”. In the foyer of the conference centre, mass-produced
plastic components will be on display alongside innovative, forward-looking
exhibits and system solutions at the trade fair which is to run concurrently.
An additional feature will be the automobile salon in which current models
of passenger cars and utility vehicles will be on show. The exhibition will
cover development of materials and components, structural calculations for
parts and simulations, mass-produced components for vehicle interiors and
exteriors, engineering services and the construction of tools and moulds.
This year, the topics on which the conference will be focusing include lightweight
construction and multifunctionality, interior and exterior, the engine, recycling
and environmental protection. The presentations will be simultaneously translated
into German or English. Among the contributors on the first day of the conference
will be John Sullivan of the Ford Motor Company, who will speak on the “Use
of plastics in body construction in coming generations of automobiles”,
followed by Dr. Thomas Schuh of DaimlerChrysler on the “Future development
of SMC technology”. Hans Rau of the BMW Group is expected to speak on
“TPU in interiors”, while Klaus Heidenreich, Jochen Roos and Frank
Reitze will give a presentation on the “BMW 8-cylinder petrol engine
with continuously variable duroplastic induction manifold” On the subject
of “Exteriors”, presentations will be given on the same day by delegates
from DaimlerChrysler (Klaus-Erik Schmid on the “Plastic outer shell”),
Adam Opel AG (Hans-Peter Gimbel on “The roof module – another step
towards modular body construction?”) and BASF AG (Dr. Achim Grefenstein
and Kaan Kaymak on “In-mould decoration instead of conventional painting?”.
The final presentation on the opening day will be on “The future of plastics
in the automobile”, given by Dr. Wolfgang Wittig of DaimlerChrysler.
The second day of the conference will be opened by experts from Volkswagen
AG with a seminar on design and materials for door panels. Representatives
of KraussMaffei and Faurecia France are also expected to speak on “Innovative
manufacturing processes adapted for the production of structural modules”,
while Marion Adelsberger, BMW M GmbH, is scheduled to talk on the subject
of “Bumper brackets in the BMW M 3 made from continuous GFT”.
Details of the full programme of events can be seen at
www.vdi.de/kunststoffe
New marking unit
Markings on moulded components whether required by law or by
the manufacturer can be produced using the new flexible Hasco marking unit.
When lot sizes, variables and materials need to be changed regularly, the
new marking unit Z 4800/... is said to make it easier to reset the markings
within the machine using marking elements and stamps without significant loss
of time. The marking unit Z 4800/... is available in three sizes. The interchangeable
insert is mounted and fixed onto a base element and is available as an uncustomised
blank component. The contour surface can be engraved or machined using EDM
or laser techniques in accordance with the customer’s design. Whilst
the base element remains in the mould, several different variously engraved
interchangeable inserts can be waiting ready to be used. The operator removes
the interchangeable insert from the opened mould, inserts a new one of the
same size and immediately restarts the production process. The company claims
this means shorter down time, less construction and assembly time and a continuous
production process.
www.hasco.com
Interchangeable insert of the marking unit