Pneumatic valve plate
with CO² deburring
CO² deburring for even more tightness in pneumatic modules.
Industrial valve solutions require high-density and leak-free media transfer. Due to the particularly delicate valve bores, conventional deburring processes are ruled out from the outset. Deburring with CO² is the solution.
# Initial situation
Form follows function. Component design as a lever for greater efficiency.
This valve plate is a pneumatic module for positioners that is used to automate various industrial systems. Various media are used, which are passed through the channels and thus assume important pneumatic control functions.
In order to achieve maximum energy efficiency with optimum switching properties, the pneumatic ducts should be as delicate and filigree as possible.
”The smaller the channels, the less air is required for switching and the less energy-intensive compressed air has to be generated.
Marco WirthChief Sales Officer
Optimum deburring for maximum tightness
From a development perspective, despite the complexity of the tool, the main challenge is the clean deburring and sealing of the fine valve bores. This is where conventional deburring processes quickly reach their limits. The aim is to achieve maximum burr-free operation without blocking or clogging the shifting process with detachable mold parting lines.
# Solution: Deburring with CO²
As the mold parting burr always occurs due to the mold parting process, we rely on high-precision and clean deburring using CO² snow and micro pressure waves. This extremely efficient CO² deburring process is based on the principle of “dry deburring” and represents an optimum alternative to classic jet deburring.
# Principle
CO² deburring can be used as an inline-capable and highly efficient process, particularly for hard plastic variants such as the PPS used here. In this process, environmentally neutral liquid CO² is fed through a nozzle, frozen at temperatures as low as minus 80 degrees Celsius and blasted onto the desired component surface at supersonic speed as so-called CO² snow. This results in several positive effects at the same time, which have an impact on the component properties in terms of the customer specification. The clear advantage: thanks to the automated process, we deburr, clean and dry the component in a single process.
Frosting
The extremely cold jet of CO² snow and compressed air hits the surface of the component, causing shock freezing and embrittling the burrs at almost minus 80 degrees.
Deburring
During the change in the aggregate state, there is an enormous increase in volume. The resulting micro pressure waves remove the protruding burrs at supersonic speed without the blasting material getting stuck in the channels.
Cleaning
In combination with solvent effects, unwanted particles, dust or other contaminants are removed homogeneously and gently from the component surface.
Drying
Thanks to the sublimation effect of the CO², the components remain dry throughout the deburring process and can be processed immediately afterwards
It all depends on the right adjustment
All process parameters are precisely adapted to the geometry and material of the valve plate with a great deal of expertise and in line with customer specifications for deburring or cycle times. Particular attention is paid here to the volume flows, the compressed air and the blasting time, which are optimized in numerous test runs in the HUB.
# Market advantage
Significant cost benefits through synergies in the process.
Thanks to the good cooperation with the customer and system manufacturer, we were able to develop a fully automated deburring concept that gives them a clear advantage over the entire series.
Maximum cleanliness and media tightness
CO² deburring ensures a clean and precise fit on the delicate and extremely fine valve bores and keeps the channels free from contamination.
Energy and cost efficiency
Our customer benefits from a compact valve unit that consumes fewer resources and can therefore be offered more profitably to the end customer. Thanks to the finely structured implementation, significantly less energy-intensive compressed air is required.
No unnecessary post-processing
Automatic cleaning and drying also eliminates the need for additional post-processing steps, which makes the process even more economical.
”Without CO² deburring, it would simply not have been possible to drill the extremely intricate and delicate channel holes.
Günter NeubauerChief Technology Officer
# Next Gen Projects
Together we create Next Gen Solutions.
“We know the production side and have the development expertise. Only those who understand both sides and bring them together will be able to demonstrate a competitive edge.”
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