“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

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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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