C1 by DME Europe

• from the heart of Europe to anywhere in the world, supporting you and your business • operating in over 100 countries worldwide • the industry’s broadest catalog for molds & components, runnerless technology, die sets and surface finishing • our products, the benchmark of high quality • industry-leading innovation and standardization since 1942 • a Milacron company with close to 5000 talented employees worldwide

FLUID TECHNOLOGY

gest inventory of standard parts in Europe, North America & Asia • next day delivery in most European regions, day after in any other European nt people and intelligent digital tools & comprehensive catalogues • worldwide network bringing service and reliability without borders

Complete turnkey solutions from drawing board to part

DME, a global company, operating in over 100

close to 5000 employees, Milacron is pres-

countries worldwide. From automobiles and

ent in more than 100 countries worldwide.

appliances to milk jugs and toothbrushes, DME

Innovative solutions and standardisation have

technologies and services help the world’s leading

lead to our current market position of industry

companies make your favorite products.

leader.

Success in today’s global market starts with the

The aquisition of Mold Masters in 2013 by

best product, at the best price, in the required

Milacron creates a leading global solutions

time frame. To achieve this, DME provides cus-

provider with enhanced operational strength,

tomers with the best blend of manufacturing,

reduced cyclicality and a strong, diverse interna-

outsourcing and strategic partners, managed to

tional footprint broadening our portfolio of excep-

be delivered right on time anywhere in the world

tional products and services to more customers in

using contemporary, sophisticated techniques.

more markets around the world.

DME, a Milacron company, is proud to be amongst the biggest players on the market along with fellow Milacron companies such as Ferromatik, Uniloy, Cimcool and brand new Mold-Masters. With over € 1 Billion in

www.dmeeu.com

sales

and

mold kits / die sets / hot runners / polishing • quality assured products • larg location • solid quality steel used in all products • service through competen

molds & components

➊

runnerless solutions

➋

die sets

➌

surface finishing

➍

FLUID TECHNOLOGY

Industry-leader since 1942

• 1940

• 1950

• 1971

• 1975

First Asian joint venture formed with the inception of Japan DME Corp. in Tokyo.

Launch of the first DME hot runner system.

• 1960

• 1970

• 1942

• 1963

I.T. (Ted) Quarnstrom founds Detroit Mold Engineering (today’s DME Company).

DME opens it’s first European settlement in Germany.

• 1964 DME’s European headquarter in Mechelen, Belgium is established.

• 1980

• 2008 DME Europe launches Quick Strip, a revolutionary part ejection tool.

• 1990

• 1999

• 2013

DME Europe integrates the company “Expulsores Girona”, in Barcelona, Spain, thus acquiring production expertise in ejector pins and sleeves and easy access onto the molding markets in the South of Europe.

Milacron and the world’s leading hot runner manufacturer Mold Masters unite - delivering an exceptional leading broad portfolio to more customers around the world.

• 2000

• 2010

• 1996

• 2011

MILACRON Inc. acquires all DME’s operations, becoming a strong partner in offering total solutions for injection molders.

DME continues to find new ways to service the customer better and faster. Investing heavily in warehousing, supply chain and customer care as well as cost & time saving innovative solutions.

• 2001 The acquisition of Reform Flachstahl, Fulda-Germany is followed only one month later by the acquisition of EOC Normalien GmbH, LüdenscheidGermany.

Special e-shop promotion: Free wooden gift box “Gouden Carolus” on all orders over €500* Gouden Carolus Classic Dark special beer This Belgian Emperor’s brew is brewed according to the classical infusion method. This traditional beer was served during the fox hunts of Charles Quint and named after his golden coins. The aromatic malts and high fermentation process combines the warm roundness of wine with the light freshness of beer.

UK: +44 2071 330037 Export: +32 (0)15 21 50 17

*Valid while supplies last.

07/10/2013

Order online or call us:

07/10/2013

Content

Introduction & Training

Surface Finishing Devices

Other Tools & Ergonomics

Diprofil Files & Tools

Stones

Abrasive & High Gloss Polishing

Abrasive Polishing Sticks, Grinding Wheels

Polishing Brushes & Felt Polishing Bobs

Rotor Cutters

Coatings

10 www.dmeeu.com www.dmeeu.com-

facebook.com/DMEEurope

Introduction & Training

07/10/2013

Content

Info

07/10/2013

Expert Service....................................................................................2 Surface Finishing..............................................................................4 Polishing Courses.......................................................................... 14

www.dmeeu.com www.dmeeu.com - 1-

DME - EOC: your expert partner of choice in all aspects of surface finishing Save time and money with us: Our aim is not just to sell; our primary goal is to be an expert partner of choice in all aspects of surface finishing! The large number of finishing tools, polishing stones, diamond pastes, tools and hand pieces etc. often makes the right choice difficult in the case of certain finishing problems with different steels and with varying starting conditions and demands in terms of the end result. Choosing unsuitable tools for certain polishing jobs and the inefficient use of polishing tools cost you time and money. We therefore feel it is essential to provide customer-specific consultation for all aspects of and problems with surface finishing. Our team which has over twenty yearsâ&#x20AC;&#x2122; experience in the fields of surface finishing and die polishing can give you the best possible advice. Fast, reliable, durable and precise: All the tools and polishing agents we sell undergo a rigorous series of tests to confirm their optimum handling, grain quality, reliability and robustness for day-to-day operations in practice in the polishing workshop of our PVD carbide coating centre to ensure that you are happy with our quality. Our versatile, carefully co-ordinated range of high-quality units and finishing tools means that we can offer you precisely the equipment you need to deal with your surface finishing problems and polishing work.

Fast deliveries Onsite interventions Polishing courses

Talk to your regional DME Polishing specialist. in German: Tel +49 2351 437248 / +49 2351 437411 DMEEU_ESS_DE@dmeeu.com

in Central Europe: Tel +420 571 619 487 DMEEU_ESS_EE@dmeeu.com

Johan Fransen

Pavel Durina

in Southern Europe: Tel +35 1917200453 DMEEU_ESS_SE@dmeeu.com in remaining countries & export: Tel +3215 215 008 DMEEU_ESS_NE@dmeeu.com

Your customer service team:

Jenny

Claudia

Maaike

Birte

Joanna

Gabriele

Monika

Kamila

Anna

Renata

Volker

Thomas

Tamas

Abelardo

Anis

Robert

Pavel

Info

Surface Finishing tools, techniques and tips

The art of finishing takes years of experience to perfect. Here are some basic principles and techniques of grinding, hand stoning and diamond polishing that will provide a good start. Surface finishing is a process that requires a variety of tools, materials, and – most importantly – highly specialized skills. One of the most technically advanced types of surface finishing is moldmaking, where the surface of the mold has a direct impact on the surface of the product being molded. Proper finishing is essential. While the art of finishing takes years of experience to perfect, there are some basic principles and techniques provide a good start. Let’s take a look at the three major processes necessary to produce a highly polished, lustrous metal surface: Grinding Hand stoning Diamond polishing.

07/10/2013

• • •

4 - www.dmeeu.com

Info

Grinding Proper grinding techniques Machining is technically the starting point of the surface finishing process, but grinding is where the real work begins. After metal is machined, its surface condition is usually rough with ridges and cutter marks. Finishers must use a hand grinder, the basic tool for light metal removal, to get the surface smooth enough to eventually finish with hand stones and, ultimately, diamond polish. Hand grinders can be used with a variety of grinding wheels and stones in a variety of shapes, sizes and grits. Selection of grit is important, because starting with too fine a grit can waste stones and time. Choose a coarser grit for roughing, and use increasingly finer grits as the surface begins to attain its final shape and size. After deciding which stone or wheel to use, mount it in the grinder while inserting the shank as deeply as possible to avoid whipping. Light â&#x20AC;&#x153;dressing,â&#x20AC;? shaping the stone to the contour of the finished surface with a dressing stone, is required each time a stone is mounted in a grinder. This ensures concentricity of the abrasive surface. Grinders have a tendency to follow the wavy contours of the rough surface, which makes it difficult to develop the smooth or flat surfaces required for subsequent stoning. Whenever possible, direct the grinding strokes at a 45 deg to 90 deg angle relative to the grooves developed in the machining process. Be sure that your hands and forearms are braced to provide maximum control over the tool, as this will influence the smoothness of the surface and the amount of finishing that will be required later. Before starting the actual grinding operation, decide how the grinder will be supported and how to hold it to permit the wheel or stone to properly address the surface. If possible, move the surface to a position that enables steady grinder control and permits easy, firm strokes.

Speed and rotation

07/10/2013

Give careful consideration to the direction of rotation. When taking a stroke in a direction opposite to a cutting tool rotation, the grinder has a tendency to run away from the cut. Conversely, stroking into the rotation of the wheel can cause the stone to cut deeper then is desired.

www.dmeeu.com www.dmeeu.com - 5-

Info Grinder speed is another important factor. Remember, the speed that matters most is the surface speed of the cutting tool against the metal. In other words, the surface speed of a small stone is less than the surface speed of a larger wheel, even though the spindle rpm is the same. Use a rheostat, a two-terminal variable resistor, if greater control of the surface speed is required. Do not try to cover too large an area at any one time. It’s difficult to maintain control and uniform pressure on the wheel over a large area. An experienced craftsman will work on a number of small areas and then blend them together. Another good practice is to crisscross the grinding strokes to ensure a uniform surface. When smoothing a surface, grind in one direction to completely cover the area being worked on. Then cross the grinding strokes until all of the previous grinder marks have been removed. Keep in mind that the finisher controls the grinder. The grinder must never be allowed to control the finisher. Power can easily result in problems so always respect the tool.

Listen and feel There are a number of important signs regarding hand grinder use that become more recognizable with experience. For instance, if the motor slows down while grinding, too much pressure is being applied. The wheel or stone cuts only while it is turning at the proper speed. The faster the cutting tool rotates, the faster the metal is being removed. A change in the sound of the grinder signifies a change in grinder speed. The amount of pressure is a matter of ”feel,” but much is learned by listening to the sound of the grinder and closely watching the surface being developed. If the stone or the wheel begins to bounce and it becomes difficult to move it smoothly over the metal surface, it’s probably caused by it being worn out-of-round, or loaded with metal chips. Correct this condition by doing a light dressing with the dressing stone.

07/10/2013

If the grinding does not remain constant, it’s due to an increase or decrease in speed. Covering too large of an area reduces control over the tool and causes fluctuating pressure, thus erratic speed. Again, work a small area at a time; then blend the areas together. The steadiness of the grinder, the evenness of the strokes and the uniformity of the pressure applied to the cutting tool will determine the quality of the job and the amount of time needed for final completion. Take care to avoid removing more metal than necessary, as this can add significant time and difficulty to a project.

6 - www.dmeeu.com

Info

Grinding tips Exercise extreme care to prevent the grinder from following the ridges and removing more material than required;

•

Whenever possible, direct grinding strokes at a 45 deg to 90 deg angle relative to the grooves developed in the machining process;

•

(Brace your hands and forearms to provide maximum control over the grinder tool;

•

(Use a rheostat, if necessary, since the surface speed of the cutting tool against the metal is paramount;

•

When mounting a stone or wheel in the grinder, insert the shank as deeply as possible to avoid whipping;

•

Choose a position that allows the grinder to be held steadily while permitting easy, firm strokes;

•

Don’t try to cover too large an area at any one time;

•

Crisscross the grinding strokes to ensure a uniform surface;

•

Listen to changes in the sound of the grinder to determine changes in grinding speed; and

•

Dress the grinder with a dressing stone if it becomes loaded down with metal chips.

07/10/2013

•

www.dmeeu.com www.dmeeu.com - 7-

Info

Hand stoning Proper hand stoning techniques Once you’ve arrived at the point where all the metal has been ground to satisfaction, the surface should be examined to determine if it’s ready for hand stoning. Check milled surfaces to see if the cutter marks are fine enough to make further hand grinding unnecessary. Surface ground finishes should be free of tears. Hand-ground finishes must be fine and shouldn’t have chatter marks or irregularities. Be sure that file marks are free of tears and waves. If all finishes are the best possible, it’s time to begin stoning. Choosing the initial grit of stone depends upon the degree of finish left by the machining, grinding or filing operation. Machining usually results in a coarser finish than grinding; therefore, a coarser grit stone should usually be used. For a ground finish, stoning can begin with a finer grit stone. Preliminary stoning may be done with a 240 grit stone to remove final dips, depressions, waves or other imperfections and achieve a flat or properly contoured surface. If defects are not too great, a 320 grit stone will be sufficient. The stone should be moved back and forth, with medium pressure applied, over the surface in a direction 45 deg or 90 deg from the direction made by the last tool marks.

Clean and lubricate stones Before using the stones, soak them in a contaminant-free, oil-based lubricant. Continue to clean the stones frequently by dipping them in the oil lubricant. Constant stone cleaning is necessary to clear away the fine metal chips that tend to clog or load up the stone. Should the stone fill with such metal chips, they could cause the cutting of deep scratches on the surface being polished. This is known as “picking up.” Stoning oil or other lubricants, in addition to keeping the stone clean, improve the cutting action.

07/10/2013

A number of ridges and high spots may appear at the start of the stoning process. All of these irregularities must be removed to obtain a truly flat and smooth surface. This is especially true if the ultimate goal is a high-luster diamond polish. Surfaces that have been ground will often have areas where the metal has been burnt by the action of the grinding wheel. These burnt areas must be removed in order to maintain a constant surface hardness.

8 - www.dmeeu.com

Info

Overlap all scratches Polishing, from a purely physical point of view, is the process of producing a series of overlapping “scratches” that get finer and finer. To accomplish this, it’s important that for each finer grade of stone used, the angle (direction) be changed relative to the marks made by the preceding coarser stone. In this way, the marks of one grit size are “erased” by the subsequent finer-grit stone. It is critical that each finer grit stone completely removes the marks of the last grit. Neglecting to do so will result in a shiny, but nonetheless, scratched surface. After each grit finish is completed, thoroughly wash the entire work area with unused stoning oil and wipe with a clean tissue to remove all particles of the grit remaining on the surface. This is necessary to ensure that none of the particles of the coarser grit will be picked up later by a finer grit stone, causing deeper scratches. To further ensure that coarser grits don’t contaminate the finer stones, lubricate the stones in a fresh can of stoning oil; not the same oil used for the coarser grit. It’s best to keep each grit of stone in a separate can.

Hand stoning tips Do not use too coarse a stone;

•

Always dress (form) the polishing stone with a grinding wheel or coarse paper to provide the maximum contact with the work surface;

•

Use care when dressing the polishing stone;

•

Use sufficient stoning oil to prevent the stone from loading;

•

Hold the polishing stone firmly for directional control, but press only hard enough to make the stone cut;

•

Make sure the stone marks from the previous grit size are removed;

•

Change stoning direction with each successive grit;

•

Clean the work area thoroughly between each change of grit;

•

Keep each grit of polishing stone in a separate stoning oil can; and

•

Exercise utmost care when stoning at an edge (parting line).

07/10/2013

•

www.dmeeu.com www.dmeeu.com - 9-

Info

Proper diamond polishing techniques Diamond polishing Diamond polishing is the last step of the polishing process – dependent on how much of a smooth luster must be achieved. However, unless all previous stoning steps have been done properly, the final finish smooth luster will not be satisfactory. If mistakes have been made in earlier finishing work, they’ll certainly show up on the surface as the final luster develops. The starting point of diamond polishing will depend, to some degree, on the sequence of stones that have been used to prepare the surface. A variety of diamond compounds – diamond particles suspended in some proprietary vehicle like an oil – are available in the marketplace. Begin by applying a small amount of coarser diamond compound to the surface being worked. Then, by means of a bristle, brass or steel brush, swirl the compound over the surface using a rotary tool at a slow speed to avoid throwing the compound off the surface. A speed of 500 rpm for roughing, and 5,000-10,000 rpm maximum for final polishing, is a good rule.

Crisscrossed brushing Using light to moderate pressure, take care to keep the brush flat to the surface to avoid cutting deep swirl marks. The same “crisscrossing” action used with stones should be employed when using diamond compound. Typically, the compound will become darker, indicating that the metal is being removed and mixed with the compound. Brush the surface until all that is visible are fine swirly marks left by the brush’s rotary action. There should be no stoning marks visible at all. If there are, apply a coarser grade of diamond compound with a brass brush and very light pressure until the stoning marks are removed. This same coarser grade should then be applied with a bristle brush to remove marks left by the brass brush. (If this coarser grade doesn’t remove the stoning marks, then a stoning operation, with a finer stone than previously used, will be required before diamond polishing can resume.)

Felting

Before progressing to a finer grade of diamond compound, thoroughly clean the mold surface to remove all residual particles of the previous grade. This is usually done with clean tissue paper or cotton and a very refined oil or alcohol. Don’t use the brushes and felts used 10 - www.dmeeu.com

07/10/2013

The next step – removing the swirly marks left by the bristle brush – is accomplished with a felt product, usually a felt “bob.” Felt bobs are available in various degrees of hardness, pre-assembled to a shank or retained in a shanked nylon holder. Mount the bob in a rotary tool and, using light to moderate pressure, polish the surface with diamond compound until all that is visible are felt swirls.

Info with one grade compound on the next grade of compound. These steps – brushing, felting and cleaning – should be followed with each grade of diamond compound to arrive at the final step. Polish the surface with fine tissue paper, felt sticks or cotton swabs with an ultra-fine grade of compound to arrive at the final high gloss luster.

Diamond polishing tips •

Apply a small amount of diamond compound at first, then add more if required;

•

Do not mix grades of diamond compound;

•

If the compound gets dry or hard, add a clean diamond thinner or lubricant;

•

Keep the brush or felt flat on the work area;

•

If the first grade of diamond compound used does not remove marks from the last stoning operation, stop and remove them with a coarser grade of compound or highly polished, shiny scratches will be present;

•

Clean surfaces thoroughly before progressing to a finer grade of compound;

•

(7) Do not use more than one grade of compound on the same brush or felt;

•

Be sure that each step completely removes the marks left from the previous step;

•

To avoid contamination, locate the polishing activity in a part of the shop away from grinding areas or in a separate polishing room; and

•

The high luster of a final mirror finish will be achieved through patience and skill.

There are no short cuts when polishing. Since a high degree of technique, even “art,” is required, it often takes years for metalworkers to become proficient polishers. Obviously, no article or list of tips can take the place of individual training under the guidance of a master craftsman.

07/10/2013

However, following the fundamental pointers outlined in this article can provide a good head start on learning this highly specialized skill and creating outstanding metal surfaces.

www.dmeeu.com www.dmeeu.com - 11-

Info

Grit comparison chart for POV

FEPA standard dense D 1181

wide D 1182

D 1001 D 851

D 852

16/20

20/25

D 602

30/35

20/30

40/45

1180 - 1000 850 - 710 710 - 600

30/40

35/40 D 427

Grit size (microns)

1000 - 850

25/30

D 501 D 426

16/18

wide

18/20

D 711 D 601

U.S. standard mesh dense

600 - 500 500 - 425

40/50

425 - 355

D/B 356

45/50

355 - 300

D/B 301

50/60

300-250

D/B 251

D/B 252

60/70

60/80

250 - 212

70/80

212 - 180

D/B 181

80/100

180 - 150

D/B 151

100/120

150 - 125

D/B 126

120/140

125 - 106

D/B 107

140/170

106 - 90

D/B 91

170/200

90 - 75

D/B 76

200/230

75 - 63

D/B 64

230/270

63 - 53

D/B 54

270/325

53 - 45

D/B 46

325/400

45 - 38

07/10/2013

D/B 213

12 - www.dmeeu.com

Info

SPI Guidelines Chart SPI Finish

Guide

Typical Applications

A-1

Grade #3 Diamond

Lens / Mirror – requires 420 SS material

A-2

Grade #6 Diamond

High Polish parts

A-3

Grade #15 Diamond

High Polish parts

B-1

600 Grit paper

Medium Polish parts

B-2

400 Grit paper

Medium Polish

B-3

320 Grit paper

Med – Low polish

C-1

600 Stone

Low Polish parts

C-2

400 Stone

Low Polish parts

C-3

320 Stone

Low Polish parts

D-1

Dry Blast Glass Bead

Satin finish

D-2

Dry Blast # 240 Oxide

Dull Finish

D-3

Dry Blast # 24 Oxide

Dull finish

This chart with typical finishes is to help in communicating with customers. Specifying these finishes on part drawings will help the moldmaker in providing the proper finish to the mold. Since the finish will vary with different materials, it should only be used as a guide.

PSP001

Sample plate REF

€ 16,7

07/10/2013

PSP001

www.dmeeu.com www.dmeeu.com - 13-

Info

Polishing courses

On course for success with DME: Try our polishing courses … beginners and advanced. In our two-day courses we give you a comprehensive overview of a very wide range of polishing strategies. We show you what steps are necessary to achieve a variety of finishes economically and reliably for a very wide range of applications. Day 1. • • • • • • • • • • • •

Theoretical principles and start of practical exercises The subjects covered include the following:

Definitions of grinding, lapping, buffing and polishing Definitions of different DIN-specified roughness ratings Achievable roughnesses as a function of different grain types, grain sizes, different binding and carrier hardnesses of different tool steels Effect of varying heat treatments for different tool steels on the polished finish Effect of pre-treatment on required polishing strategy Systematic design of a mould polishing finish Correlation of polishing input to desired outcome Avoidance of manual polishing errors (geometry) Avoidance of manual polishing errors (structure) Polishing repairs following mechanical or chemical damage What PVD carbide coatings can be used to address various problems (e.g. mold release, deposits, gas evolution, abrasive wear etc.) with different (filled) injectionmolded masses Sensible combination of different polishing instruments - the polishing workplace tailored to your needs

Once the theory section is complete, the first practical exercise involves the use of different polishing agents. To get a feel for the different polishing tools, you work in groups with different grain types and grain sizes with varying binding and carrier hardnesses with the aim of achieving a superfinished plane workpiece.

Day 2.

Practical principles for achieving polished finishes on tools

07/10/2013

Each polishing course participant works on two mold inserts specially manufactured for the courses with the aim of achieving a superfinished product. No strictly specified stages are followed; instead alternative finishing options are demonstrated with the aim of determining the most efficient means of reaching the target of a superfinished product.

14 - www.dmeeu.com

Polishing courses

Info

Exercise 1 Achieving a superfinish with rotary tools Alternative finishing methods are presented to the course participants. Each course participant decides his own finishing strategy for achieving the same final result in each case. The different finishing methods are then discussed, unnecessary and wrong finishing stages are explained, thus revealing the way to achieve an efficient mold finish with the optimum result for the specific purpose. Exercise 2 Achieving a superfinish with linear tools This primarily involves the use of hand filing machines and ultrasonic polishing systems. Here, too, various finishing options are tried out and then discussed. The purpose of dividing up into different finishing options is to demonstrate that the different polishing strategies can result in the same outcome. Our aim is not to force any generally applicable “formula” on the course participants. Instead, we wish to stimulate people to think about certain finishing methods and to identify and encourage individual aptitudes among the course participants to ensure that sustained efficiency is achieved in the polishing work carried out by your company. Other specialised courses that we offer: • •

In-house training courses on our customers’ premises Special polishing courses for our customers in our training rooms

Firstly we analyse your finishing problems on-site and then draw up a training programme tailored specifically to your requirements.

07/10/2013

Please ask for details of the courses we offer.

www.dmeeu.com www.dmeeu.com - 15-

07/10/2013

16 - www.dmeeu.com

07/10/2013

www.dmeeu.com www.dmeeu.com - 17-

07/10/2013

18 - www.dmeeu.com