Mould design - Konstruktionsbüro Hein GmbH

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Konstruktionsbüro Hein GmbH – Your partner for solutions
Our team / contact information
We are a team of specialists with professional backgrounds in practice.
We strive for innovations, challenges and fair co-operation.
E-mail – Technology workshop:
Konstruktionsbüro Hein GmbH
Marschstraße 25
D-31535 Neustadt (near Hanover)
Germany
+49 (0) 50 32 / 63 15 1
+49 (0) 50 32 / 63 11 6
www.KB-Hein.de
info@KB-Hein.de
tt@KB-Hein.de (Nur für TT)
Data exchange: ftp-Server (Zugangsinfo per E-Mail)
How to reach us (map): www.KB-Hein.de

Konstruktionsbüro Hein GmbH – Your partner for solutions
Product development / product optimisation
Description:
Co-operation project „Koralle“ (Euromold 2007)
Your advantage:
Ophthalmoscope with 26 lenses
Otoscope
Insert moulded PCB
3
Product development or optimisation of
your workpiece’s geometry – whatever
the task is, we will assist you with our
entire range of services, consulting and
training with regard to innovative ideas,
choice of material(s), procedures and
technologies up to the implementation
of a production ensuring process
reliablity.
We can offer you a single service as well
as a complete service.
The properties of the workpiece will be
designed optimally according to your
specifications using FEM analysis and
injection moulding simulation.
Product development for plastic parts are
effected plastics-oriented with averaged
tolerances and draft angles.
Assembled parts are examined using
computer tomography.
• cost-reduction for tool design
• reduced cycle times
• better quality of the workpiece
• shorter project time
• considerable reduction of possible
mistakes
Contact socket -
no burrs on the inside despite filigree
separations

Description:
Your advantage:
Application:
Required data:
Konstruktionsbüro Hein GmbH – Your partner for solutions
FEM analysis For strength - acoustics – dynamics
Fixing of media-conducting pipes
4
Simulation instead of trial-and-error
using FEM– (finite elements method)
analysis
For almost all materials (metal, glass,
plastics).
FEM systems for calculating strength
are generally divided into “linear“ and
“non-linear“ approaches.
The “non-linear“ approach is closest
to reality when plastic parts are
concerned.
Parts characteristics can already be
examined and analysed before the part
is actually being manufactured.
Collision observations are ensured
using work movements and may be
verified in retrospect using computer
tomography.
Detail of a seal
Sealing behaviour
Acoustics
Thermal insulation
Dynamic deformation
Considerations regarding strength
Unwinding behaviour
3D data, load points,
stress-strain curves of the material

Konstruktionsbüro Hein GmbH – Your partner for solutions
Description:
2) Injection moulded parts from pilot tools or
experimental tools (see pic. below)
already have most of the properties of the
series production parts and may be
produced with a good quality surface
depending on the part design. For most
applications, materials can be supplied in
the desired colour and strength.
Prototyping / prototooling
5
On demand we are able to provide you
with a list for each material indicating
all material properties and prameters
regarding strength (e-Modul).
Prototypes and/or small batches can
be manufactured from elastomers
(also rubber) and thermoplastic
materials to thermosetting plastics and
even using metal pressure moulding.
1) Using the SLS technology parts on the
basis of PA12 materials can be
manufactured in a favourable priceperformance
ratio in small batch
numbers.
The parts (see pic. on the left) show
the typical rough surface and may be
coloured with some limitations.
3) Parts from vacuum moulding are
mostly formed on a PU material basis.
Colouring can only approximate the
final colour for series production.
Strength can be dimensioned for high
loads using glass fibres.

Description:
Your advantage:
Required data:
Konstruktionsbüro Hein GmbH – Your partner for solutions
Step 1 Injection moulding simulation
cross member of approx. 1.4 m length
6
An injection moulding simulation
shows filling and shrinkage while
including the influence of the tool
(e.g. temperature regulation) – before
the tool has actually been designed.
The simulation allows for recognising
possible defects of the moulded part
at an early stage thus providing the
basis for parts optimisation.
• higher processing window at
the machine
• calculable process window
• reduced reengineering
• early detection of part defects
• cost reduction
• easier planning of through-time
• controlled and reduced
distortion
• early recognition of weld lines
and air traps
• optimum design of feed gate
• low shut-off pressure
cross member with temperature regulation of the tool
• 3D data (e.g. step files)
• exact name of material or
rheological data of material
• 2D or 3D data of the actual
state inside the tool
(temperature regulation and
feed)

Konstruktionsbüro Hein GmbH – Your partner for solutions
Description:
Your advantage:
Required data:
Step 2 Parts optimisation
7
On the basis of the results from
injection moulding simulation the
workpiece can now be optimised.
This may include:
• process optimisation
• geometrical optimisation
• material Optimisation
• flow Optimisation
• feed optimisation
• temperature regulation close to
the contour
• seperate inserts for temperature
regulation against „hot spots“
• modified seperation for
ventilation
• negative correction
• optimised packing pressure
• alternative production technologies
• lower production costs
• better part quality
• faster project cycle
• bigger process window
• reduced distortion
Pictures by Hirschmann Electronics (überzeichnet dargestellt)
before after
You provide us with your solids as well
as the data of adjacent parts which we
need for optimisation suggestions.
Also, the exact name of the material
including rheological and mechanical
data are required.

Description:
Your advantage:
General:
Konstruktionsbüro Hein GmbH – Your partner for solutions
Step 3 Temperature regulation close to the contour
8
In an injection moulding simulation
the temperature regulation is already
being dimensioned before the tool
itself has been designed.
The simulation informs about the heat
exchange on the tool surfaces and
about its influences on the product.
The temperature regulation system is
designed in order to be effective
close to the contour using either
drilling, laser melting, vacuum brazing
or special materials.
• short cycle time
• reduced distortion
• less wear at the tool
• adhesions on the tool are
reduced
• high quality of moulded part
(Pictures by Phoenix Contact / Blomberg)
The correct temperature of the female
mould wall is crucial for obtaining a
good part quality. Any plastic material
has its own determined mould wall
surface temperature that shold be
attained if possible.

Konstruktionsbüro Hein GmbH – Your partner for solutions
Description:
Your advantage:
Required data:
Please note:
Laser melting for inserts for temperature regulation
9
The tool inserts that are manufactured
using this method already integrate
temperature regulation close to the
contour. They are made of resilient hot
work steels (hardness of more than
HRC 54) using metal powder in a
laser melting process (layer
composition).
The minimum thickness of a layer is
0.025 mm (2008).
We initiated vapour diffusion tests (see
image on the left) using pressurised
water of up to 150°C that proved a
diffusion resistance of 100%.
2 manufacturers (2 samples) had
thicknesses of up to 0.5 mm.
Temperature regulation close to the
contour in narrow and hot areas
with resilient mould inserts.
The geometries to be produced are
processed using an STL file.
The roughness of the surface due to
the temperature regulation process is
smoothed using a grinding paste and/or
coating and ensures the temperature
regulation together with appropriate
temperature control units.
The outside contour should include an
allowance for finishing.

Description:
Mould design
3-disc tool for thread-spindling-off
Special procedures:
Konstruktionsbüro Hein GmbH – Your partner for solutions
10
Tool design
e.g. for:
injection moulding tools,
hot press tools,
pressure moulding tools,
elastomer moulds
Tool with slide bar redirection GIT tool for charger tray
vacuum brazing for inserts
(upper discs)
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Examples:
multi-component;
sandwich; foaming;
tandem solutions; collapsible cores;
unscrewing solutions;
transfer moulding;
gas injection;
gas cooling;
gas counter-pressure;
external gas moulding;
water injection

Konstruktionsbüro Hein GmbH – Your partner for solutions
Description:
General:
11
NC programming
We offer:
(Pictures by OpenMind)
• complete service from design to
production
• elekcrode design
• NC programs
• CAD/CAM service considering the
workshop
• innovative milling strategies for your
requirements
For a start: CAM service on your
premises.
We adapt
the NC programs
according to
your specifications!

Description:
Your advantage:
Scope of application:
Konstruktionsbüro Hein GmbH – Your partner for solutions
Gas injection technology GIT
cap,
pictures by
Phoenix Contact
12
With the aid of cross sections the gas
is guided to the relevant areas where it
compensates volume contraction.
Thus, the gas assumes the role of the
packing pressure at a constant level
for the entire workpiece.
• controlled packing pressure
• tension-free and straight part
• better cooling effect
• low shut-off pressure
• reliable process at a high quality
• for parts with different wall thicknesses
• for parts that need to be produced with
low pressure and low distortion
Polarisation films on the overhead
projector (see picture on the left) expose
the lower potential for tensions in the
workpiece with GIT.

Konstruktionsbüro Hein GmbH – Your partner for solutions
Description:
Injection inlet
Your advantage:
WIT Water injection technology
13
For water injection, the excellent thermal
conductivity of water is used to achieve
a favourable cycle. Different procedures
such as partial filling or auxiliary cavities
can be applied.
The picture on the left depicts the small
inlet and outlet orifice for water injection
with a blind hole.
The centre-left picture shows the
homogenous wall thicknesses that are
produced.
• short cycle times for appropriate
geometries
Handle with recesses Partner project of companies Stieler and Hein
With this special WIT process (example: handle), the part is partially filled with water which
is then pressed, at high pressure, into the blind hole that has been formed. The water is
then extracted well-controlled from the part in order that the part leaves the tool almost dry.
Please note:
Chances and limits of water injection are:
1) Only round geometries such as pipes for
the passage of media, can be
manufactured with relatively constant
wall thickness.
2) If a clustering of the mass occurs a
shrinkage of the volume cannot be
compensated as easily as when gas
injection is used.

Description:
Training courses
Konstruktionsbüro Hein GmbH – Your partner for solutions
14
Our courses and training programmes are
always adapted specifically to the
participants requirements (company
course).
According to our motto
„From idea to series production“ in
plastics technology we are able to
establish a training concept that meets
your needs.
Your advantage: • close to practice
• with reference to your project(s)
• individual
Examples:
Training location:
Physics of polymers
Recognising part defects
Project training for design engineers
e.g. design of feed gate
e.g. temperature regulation
Design with regard to injection moulding
e.g. product development taking into account
plastics and tooling issues
Mould filling analyses/ distortion
calculation
Simulation including temperature regulation
Cost-efficiency from product development
to the injection moulding machine
Over the last few years we often held
trainings at our customers’ premises as it is
sometimes easier to include current
projects and difficulties into the training
process.
Alternatively, our training centre is a tenminute
walk from Neustadt train station.
After an intense day of courses, the
recreational values of nearby lake
Steinhuder Meer and its surroundings invite
you to relax. A comfortable hotel is waiting
for you to rest in order that you can enjoy a
fresh start to the following day of training.

Konstruktionsbüro Hein GmbH – Your partner for solutions
Description:
Example:
Examples:
Sink mark
Air trap
Vacuole in part reinforced with glass fibresl
Your problem is our job
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We interpret defects (here: sink
marks) in the customer’s workpiece
and work on constructive solutions to
eliminate them.
Injection moulding simulations ensure
that there are no problems with
ventilation or we work out new
solutions for ventilation together with
our customer.
Part failure
When the part fails (void) we use fem
analysis and injection moulding
simulation to develop constructive
modifications of the part and
otimisations of the tool (e.g. for the
gate) that ensure that the part meets
the requirements in the future.
Make use of our possibilities for
solving your problems.

Technology Workshop for
12-15 expert lectures
50-60 exhibitors
300 – 400 participants
Product Development
Mould Design
Injection Moulding
When: End of February /
beg. of March
(see www.Kb-Hein.de)
Where: Neustadt (near
Hanover, Germany)
We are looking
foward to your visit!
More information,
registration forms and
reports can be
downloaded at:
www.Kb-Hein.de
A place to present problems, discuss solutions, exchange
knowledge, get into contact and find co-operations.