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Georg Kaufmann InnovationGeorg Kaufmann Tooling
Press ReleaseCombining organic sheet thermoforming with long-fibre direct injection moulding
K 2013: Kaufmann exhibits mould for series production of lightweight fibre composite partsBusslingen, October 2013. – An innovative mould for the series production of lightweight fibre composite parts has been developed by Georg Kaufmann AG, Busslingen/Switzerland, within the scope of a joint project that goes by the name of LIPA (Lightweight Integrated Process Application). Cut-to-size blanks of Tepex organic sheet – a fabric-reinforced thermoplastic – are first pre-heated and then placed in the mould, where they are thermoformed and at the same time provided with moulded-on ribs, bearing eyes and other working parts with the aid of the long-fibre direct injection moulding process developed by the firm of Arburg, Loßburg/Germany. The result is a lightweight part of extremely high strength and stiffness. The entire production process will be demonstrated at K 2013 (Düsseldorf, 16th to 23rd October 2013) on the Arburg exhibition stand (A13 in Hall 13) on a hydraulic Allrounder 820 S equipped with servo hydraulics. The machine and mould will be producing a demonstration part similar, for example, to a swing arm for a bicycle or a structural element in a car seat.
For the production of the demonstration lever, two cut-to-size organic sheet blanks of different thicknesses are gently heated up to thermoforming temperature in synchronism with the moulding cycle of the machine. A robot equipped with a vacuum gripper safely transfers the blanks with a minimum of delay into the mould cavity where they are thermoformed into a W-shaped profile. This not only increases the rigidity of the lever but also ensures a full-surface, firmly pressed, positive connection between the two component sheets. Stiffening ribs and an edging of long fibre-reinforced
Georg Kaufmann Formenbau AG Rugghölzli 3 CH-5453 Busslingen
Telefon +41(0)56 485 65 00 Fax +41 (0)56 496 54 00
Press Release, page 2 from 4 „Combining organic sheet thermoforming with long-fibre direct injection mouldingK 2013: Kaufmann exhibits mould for series production of lightweight
fibre composite parts“
plastic are then injection moulded onto the organic sheets. As the temperature of the organic sheets is only slightly below the melting temperature of the base polymer, a perfect bond is ensured. For the same reason it is also possible to produce moulded-on elements (e.g. screw bosses) by injecting through the organic sheet without causing any damage to the fibre structure in the moulded part. In order that it can be connected to a mating part in a downstream process, the demonstration lever is provided with a corresponding hole during the moulding operation without adversely affecting the fibre structure.
In developing and producing this demonstration piece, the partners to the aforementioned joint project not only show that lightweight fibre composite parts can be mass-produced but also demonstrate a number of innovations that are decisive both for the economical efficiency and for the functionality of the parts:
Improvement in the lightweight coefficient through local application of different thicknesses of organic sheet according to the load distribution within the moulded part.
Reliable bond between the component organic sheets through full-surface, firmly pressed, positive connection.
Creation of hole in the organic sheet without damaging the fibre structure.
Encapsulation of the exposed fibres of the cut-to-size organic sheets through a moulded-on all-around edging.
Reduction in heat-up temperatures for the organic sheet through minimum temperature loss during the moulding cycle.
Long-fibre direct injection moulding readily permits flexible combinations of material through variations in fibre length and content.
Significant cost benefits offered by long-fibre direct injection moulding thanks to use of cost-saving starting materials.
Georg Kaufmann Formenbau AG Rugghölzli 3 CH-5453 Busslingen
Telefon +41(0)56 485 65 00 Fax +41 (0)56 496 54 00
Press Release, page 3 from 4 „Combining organic sheet thermoforming with long-fibre direct injection mouldingK 2013: Kaufmann exhibits mould for series production of lightweight
fibre composite parts“
Project partners: Arburg: Injection moulding machine equipped with an injection unit in
which the long glass fibres are cut and mixed into the melt directly from the roving
Bond Laminates: Fabric-reinforced sheets with thermoplastic matrix (Tepex organic sheet)
FPT Robotik GmbH & Co. KG: Design and production of process automation system
Georg Kaufmann Concept GmbH: Part design; Moldflow simulation of injection moulding operation
Georg Kaufmann Formenbau AG (LIPA initiator): LIPA mould, process design and engineering
HRS: Hot runner system with needle valve nozzles suitable for LFRTsILK/LZS GmbH: Calculation and simulation of the part Kistler Instrumente AG (LIPA partner): Mould sensor technologyKrelus Infrared (LIPA partner): Infrared heater and control unit Lanxess Deutschland GmbH: Cutting pattern organic sheet, drape
simulation of the part SKZ - KFE gGmbH: Process monitoring and quality control
Further information :
Georg Kaufmann Formenbau AGDipl.-Ing. Christian Götze, Head of R&D Rugghölzli 3, CH-5453 Busslingen/SchweizTel.: +41 (0)56/485 65 48, Fax: +41 (0)56/496 54 00, E-Mail: [email protected], Internet: http://www.gktool.ch
Editorial contact and hard copies:Dr. Diether Burkhardt, KONSENS Public Relations GmbH & Co. KG,Hans-Kudlich-Straße 25, D-64823 Groß-UmstadtTel.: +49 (0) 60 78/93 63-0, Fax: +49 (0) 60 78/93 63-20E-Mail: [email protected]
Dear Colleagues,an MS-WORD file of this press release in English and German and printable-grade copies of the enclosed images are available for download at http://www.konsens.de/kaufmann.html
Georg Kaufmann Formenbau AG Rugghölzli 3 CH-5453 Busslingen
Telefon +41(0)56 485 65 00 Fax +41 (0)56 496 54 00
Press Release, page 4 from 4 „Combining organic sheet thermoforming with long-fibre direct injection mouldingK 2013: Kaufmann exhibits mould for series production of lightweight
fibre composite parts“
Demonstration lever; top: schematic depiction with enlarged detail of overlap area; bottom: actual lightweight fibre composite partSource: Georg Kaufmann, Busslingen/Switzerland
Georg Kaufmann Formenbau AG Rugghölzli 3 CH-5453 Busslingen
Telefon +41(0)56 485 65 00 Fax +41 (0)56 496 54 00