“Workpiece optimized machine solutions for parts cleaning” Dipl. WI-Ing (FH) Muhammer Kör Date: 24.10.2017 Member of stoba Group www.stoba-Memmingen.de
“Workpiece optimized
machine solutions for parts
cleaning”
Dipl. WI-Ing (FH)
Muhammer Kör
Date: 24.10.2017
Member of stoba Group
www.stoba-Memmingen.de
Who is stoba & what are the core competences
Cleanliness requirements on basis of a realized project
Introduction of the realized cutomer project
Reached cleaning results
Summary
28.09.2017 2
Overview
Stoba core competences
Stoba ECM/PECM Technology
Machines for Electro-Chemical
Machining (ECM/PECM)
CNC 5-Axis compactmilling center
Fixture, automation & cleaning machines
Stoba Milling/Drilling
Technology
CNC 5-Axis Laser-drilling machining center
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Cleanliness requirements for engine components
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General definition residual contamination:
Residual contamination consists of solid particles and soluble substances that persist on the surface of the component after the final step in manufacturing. The dirt particles, especially hard particles cause severe damage and reduce the lifetime of the product.
Hard particle All particle
Machining chips Fibrous material, Fiber
Grinding residues Coating particles
Metal hydroxide Plastic particle
Ceramics Hard particle
Definition particle size in engine systems
25 µm < x < 400 µm
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Realized customer project
Customer requirements
Part High-pressure fuel distributor
Material 1.4301
Dimension L: 400 mm (Ø 20 mm)
Application Deburring & cleaning
Annual volume 0,8 - 1,0 Mio.
Types 2 (without changeover)
Cycle time < 25 sec per part
4-6 hole intersections (Ø 1,00 – 3,50 mm)
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Cleanliness requirements
Particle size(metallic / nonmetallic)
Amount
25 … 50 µm 150
50 … 100 µm 100
100 … 150 µm 33
150 … 200 µm 10
200 … 400 µm 2
> 400 µm 0
Fibers 10
Cleanliness measurement only applicable for fuel-touching areas (internal areas)
Particle size : Definition in length
Amount: Piece
Maximum width of 5 biggest particle: 50 µm
Realized customer project
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Manufacturing process steps
CNC machining
Pre-cleaning
ECM deburring
Neutralisation (desalting)
Post-cleaning & drying
Handover clean room Pre-cleaning
ECM deburring
desalting
Post-cleaningClean room
Part flow
Leak test
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After pre-cleaning After ECM deburring
Post-cleaning & Drying
Leak test
Assembly
Burrs and dirt
residues
Metal hydroxides,
salt particles and
dirt residues
Manufacturing process steps
Air purity Handling
ChamberFilter
technology
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Realisation of post-cleaning machine
Pre-cleaning
ECM deburring
Post-cleaning
Clean room
Automation
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Pre-cleaning
ECM deburring
Post-cleaning
Clean room
Air purity
Air path from „inside to outside“
Setting of compression zones
Implementation of clean room units
Controller for regulation of the ventilation system performance
Air path
Assembly, leak test
and package
Overpressure
5 mBar
Atmosphere
1000 mBar
Overpressure
10 mBar
Overpressure
15 mBar
Customer
clean
room
Realisation of post-cleaning machine
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Handling
Rotary table with 4-fold clamping unit
Parts clamping in the workpiece holder
Cleaning of the workpiece holder in each flow
Realisation of post-cleaning machine
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Chamber
12
Part loading
4x cleaning
2x drying (hot air & vacuum)
Part unloading
Layout of the chamberC1
C4C3
C2
D1
D2
Realisation of post-cleaning machine
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Chamber
13
Wet chemical process with spray and floodcleaning
Integrated blast connection and lances
High pressure and flow rate (e.g. 267 l/min)
View: Cleaning chamber
Realisation of post-cleaning machine
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Chamber
14
C1
C4C3
C2
D1
D2
Flood cleaning Spray cleaning
Realisation of post-cleaning machine
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Chamber
15
Cleaning strategy
Inside Outside Medium
Chamber1 Spray Nozzle Chemistry
Chamber2 Flood Nozzle Chemistry
Chamber3 Spray Nozzle DI-Water
Chamber4 Flood Nozzle DI-Water
Flooding unit Jet-lance
Realisation of post-cleaning machine
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Chamber
16
Cleaning strategy
Inside Outside Medium
Chamber1 Lance Nozzle Chemisty
Chamber 2 Flooding Nozzle Chemistry
Chamber3 Lance Nozzle DI-Water
Chamber 4 Flooding Nozzle DI-Water
Spray-
lance
Realisation of post-cleaning machine
28.09.2017
Chamber
17
Flooding unit
Cleaning strategy
Inside Outside Medium
Chamber 1 Lance Nozzle Chemistry
Chamber2 Flooding Nozzle Chemistry
Chamber 3 Lance Nozzle DI-Water
Chamber4 Flooding Nozzle DI-Water
Realisation of post-cleaning machine
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Filter
technology
Filter size
1. Stage 2. Stage
Chamber 1 10 µm --
Chamber 2 10 µm --
Chamber 3 1 µm 5 µm
Chamber 4 1 µm 5 µmFilter unit
Realisation of post-cleaning machine
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Reached results accord. VDA Bd. 19
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Reached results accord. VDA Bd. 19
Largest metallic particle
Second largest metallic particle
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Reached results accord. VDA Bd. 19
Largest nonmetallic particle Second largest nonmetallic particle
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Reached results accord. VDA Bd. 19
Largest fiber
Summary
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Cleaning is more than parts „washing“
Analyzing of the total manufacturing steps before layouting the cleaningmachine concept
Considering of all influencing parameters according to the cleanlinessrequirements
Stoba experience:Fine-cleaning = Spray-cleaning with lances and nozzles
Stoba Sondermaschinen GmbHMittereschweg 187700 MemmingenGermany
Thank you
for your attention
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