01News

Gearing technology from MS-Schramberg

magnetic and precise

Picture 1: Gear measurement on the coordinate measuring machine

 

As a result of technical progress and technological change, especially in the automotive industry, there are now applications that integrate gearing and magnetic components into the same assembly or in one single component. MS-Schramberg recognised this trend some time ago and has consequently strengthened its expertise within the area of plastic gearing systems. As a result, we are now able to provide our customers with optimal combination solutions comprising magnets and precise gearing. Here, we also draw on our many years of experience in 2-component injection moulding as well as in the overmoulding of magnet insert parts. -> see picture 2

 

Design, simulation and optimisation of gear parts in conjunction with injection moulding

Through the use of various simulation techniques, such as FEM structural mechanics or virtual tool trialling, we are able to carry out comprehensive product optimisations as early as during the concept phase. This allows the tools to be correctly designed in terms of temperature control and stability well in advance. The primary focus is the optimal design of the gearing component and its connection concept; this enables the targeted prevention of unwanted shrinkage and warpage and thus guarantees the best-possible part quality.-> see picture 3 to 5

 

Effective gearing correction

In order to achieve the desired component precision, a geometric fine adjustment of the shape must be carried out. The use of exact measurement technologies, such as computer tomography and the coordinate measurement technology, provides us with the measured values required for the corrections.  

With reverse engineering software designed for this purpose, we can use the measurement data to carry out effective correction of the injection moulds. This allows the optimisations to be carried out in a targeted manner. Overall, the individual correction of a single tooth guarantees a fully functional gear.

As a result of the precise production technology used within our toolmaking procedures, we are able to precisely illustrate corrections for the injection mould. The advantages of this continuous process chain are obvious: top quality and rapid series-production readiness. -> see picture 6

 

Exact measuring technology
To carry out the quality assessment of gear parts, MS-Schramberg mostly uses tactile measuring technology, and special gear testing procedures. In addition, we use industrial computer tomography (ICT) as well as optical 3D measuring technology (e.g. focus variation).

With the aid of super-precise, tactile 3D coordinate measuring devices and minuscule ball tips at sensing devices, extremely small gears and tight tolerances are able to be verified when taking into account measurement uncertainties. Here, a rotary table used as an additional axis is useful for recording gears across their entire width and contour. Double-flank roller testing equipment and special measuring devices are used to determine the diametrical dimension over two spheres in order to quickly and easily verify the quality of the gears during series production. -> see picture 1 and 7

See picture 2: Two-component moulded part NdFeB37/60 p Matrix material PA 12 Plastic POM

Picture 3: Influence of the number of gating points on the roundness

Picture 4: Simulation of the filling process

Picture 5: Minimisation of warpage through optimised geometry

Picture 6: Geometry recording through ICT

Picture 7: Graphically supported programming of the gear measurement on the coordinate measuring machine