Aug 4 2014
Alicona Manufacturing, in collaboration with Makino, will present an innovative CLM Machine at this year’s Control trade fair. This high precision EDM machine is based on closed-loop technology and offers an end-to-end solution for production by enabling self-optimized performance while increasing machine accuracy and eliminating clamping errors.
Control 2014: Alicona Manufacturing and machine manufacturer Makino will present a high precision electrical discharge machine (EDM) based upon True AdaptTM Closed-Loop Manufacturing technology as developed through the collaboration of Austrian based Alicona Imaging GmbH andUS based EDM Department. The state-of-the-art machining center with integrated 3D measurement center offersan end-to-end solution for production as it allows self-optimized performance through high resolution, non-contact 3D metrology fully integrated into a precision machine tool. This new processing method eliminates clamping errors and has the potential to increase machining accuracy fourfold within EDM, grinding, laser and milling industries.
Formed through the collaboration of optical metrology expert Alicona Imaging and manufacturing specialist EDM Department, Alicona Manufacturing is proud to debut the latest generation of EDM machining centers. At Control 2014, Alicona Manufacturing and machine manufacturer Makino will together bring this manufacturing generation to the next level through the presentation of a unique combination of high resolution optical 3D measurement technology and automated machine programing. Based upon an “Industry 4.0” or “Smart Manufacturing”, Alicona Manufacturing is setting the trend of integrated manufacturing by offering a novel production system where components are measured directly inside the machine.The internal measurement evaluates possible deviations from the target geometry and reports them directly to the machine whicheliminatesthe need to remove parts for measurement. Based upon the internal evaluation, the machine automatically modifies the process parameters for further manufacturing. As a result of this closed loop “processing-measuring-modifying-processing”, users experience up to four times the accuracy in comparison to traditional measurement methods.
CLM Machine
Alicona Manufacturing’s CLM machine is composed of a Makino machining center and an integrated optical 3D measurement sensor from Alicona. This technology allows miniaturized EDM components with complex geometries to be manufactured using continuous high resolution measurements for inspection. High measurement speed in conjunction with high vertical resolution enables machine to machine communicationwhile measurements of form, position, and surface finish ensure quality and adherence to various tolerances.
True AdaptTMTechnology Benefits
Mark Raleigh and Dr. Stefan Scherer, Co-CEOs of Alicona Manufacturing, agree that enabling self-controlled production through this pioneering technology will present worldwide users with a multitude of benefits. A few of the benefits include: up to a fourfold increase in machining accuracy; elimination of clamping errors; automated quality assurance; 25% resource savings; a more efficient deployment of personnel and shorter lead times at a better output ratio. Mark Raleigh is confident about this revolutionary processing method as he explains, “The integrated measurement sensor verifies what the machine is currently doing. As a result, the production accuracy is increased while adverse effects of the environment are reduced.” Alicona Manufacturing’s CLM machine, although offering diverse applications, is dominantly applicable within the mold and tool making industries. To quote Dr. Scherer, “The main CLM application clearly lies in mold and tool making. Our area based, dense and high resolution metrology allows better control of the production process than a simple tactile point measurement for example.”
Closed-Loop Manufacturing DieCasting Industry
One practical example of CLM application is in the die casting industry in the production of slides used for demolding of injection molding components. The geometry of the slide's tip is crucial as it has to engage perfectly with its counterpart. If angles of up to 90° and lengths of only a few millimeters do not comply with the CAD model exactly, the slide has too much clearance inside its counterpart which may lead to deformation when polymer is injected. In the case of deformation, tight form tolerances can no longer be maintained and the operator might have to change the slide.
When it comes to slide production the use of closed-loop manufacturing guarantees adherence to all tolerances within µm range. The extremely high machining accuracy enables error free application and a long service life. Benefits for the diecasting industry include savings as a result of resource efficient production and shorter processing times due to the reduction of slide changes.
Source: http://www.aliconamanufacturing.com/