To identify the optimal trimming solution for polyurethane components requires a lot of experience in all type of processes, including punch and die as well as flexible trimming. There are many small suppliers for each of these processes, all providing only their special type of machinery. It is easy to understand that, with certain compromises, every solution might be applicable to nearly every job: However, there are enormous disadvantages possible in terms of costs and quality. To find the ideal solution requires a supplier who has both types of processes in their scope of supply, punch and die as well as flexible solutions. Krauss Maffei is one of the worldwide suppliers who meets this requirement. Punch & Die solutions are familiar at the higher volumes of the automotive industry. This process is quick (as fast as 30 sec) and provides components free of any re-work requirements. The claim of excellent trimming quality requires a precision of the slider-driven cuts of less than 1/100 mm following the movement of the upper platen of more than 1200 mm. This level of precision requires a highly sophisticated design, as well as craftsmanship, thereby limiting this capability to a few companies worldwide. Waste is removed automatically so the process can be automated and provides components free of any re-work requirements. On the side of the flexible solutions, the milling process is known to be very feasible, particularly for semi-rigid foams and multi-layer parts such as instrument panels or door panels. Cycle times are considerably higher in comparison to punch and die processes, however the system enables the production of several different components on one machine. In most cases, parts need to be cleaned afterwards to be prepared for the next process or for shipping. Laser trimming systems were developed a few years ago and they looked like the new stars on the horizon of flexible trimming solutions. Touch-less and without any media, the material is melted or sublimated. Beside the cut-away areas, no waste is created. The system allows for fast working speeds and takes the robots guiding capabilities to its limits. For many polyurethane components, especially soft polyurethane parts, the waterjet cutting process is used. Highly pressurized water exits a nozzle with ultrasonic speed to trim the parts without touching them. In some cases a punch & die solution as the core process does not achieve a 100% trim line on the component. As an additional step, routing is applied in many known cases within the car industry. Flexible trimming solutions need a fixture to adjust the part to the process. It is obvious that the accuracy and capability of the fixture significantly affects the accuracy and quality of the entire tnmming process.
Trim & punch-technologies for IPs and door panels
Reingungs- und Stanztechnologien für Instrumententafeln und Türinnenverkleidungen
2009
8 Seiten, 7 Bilder
Aufsatz (Konferenz)
Englisch
Injection Molded Polypropylene Door Trim Panels
SAE Technical Papers | 1970
|Materials For Automotive Interior Door Trim Panels
SAE Technical Papers | 1988
|Materials for automotive interior door trim panels
Tema Archiv | 1988
|Materials for automotive interior door trim panels
Kraftfahrwesen | 1988
|