Bearbeitungsrichtlinie En

Machining guideline Mould construction

That´s where

we are strong.

2010

Index

ejector set 23 / 24

7

25

11

4 - 6 8

9

321

10

20

13

18 / 19

1226

14 - 17

27

28

.................................................

O - ring seal 22.................................................

roughing 3D 29.................................................

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flame cutting

chamfers

top lock

Meusburger bores patternbores pattern - special

threads

contentcooling circuit

eye bolts

slide

finishing

inclined pin

roughing

30.................................stress-relieving heat-treatment

anti-twist protection

interlock

distortion

thermal insulation board

27.04.2011 Blatt 2/31

Meusburger Georg GmbH & Co KGFormaufbauten

Kesselstraße 42A-6960 Wolfurt

T 00 43 (0) 55 74 / 67 06-0F 00 43 (0) 55 74 / 67 06-12

www.meusburger.comoffi [email protected]

content

O-ring seals

eye bolts

roughingfinishing

top lock

ejector setanti-twist protection

flame cutting

chamfers


bores pattern - special

Meusburger bores pattern

threads

cooling cicuit

distorsion

slide

inclined pin

interlock

page 12page 13

page 11

page 23/24page 26

page 7

page 25

page 28

page 8

page 4- 6

page 9

page 21page 22

page 27

page 10page 20

page 18/19

page 14-17

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Meusburger bores pattern / Ø 14 - Ø 26

Ø 20 / M 10

Ø 14 / M 8

Ø 26 / M 10

16

1632

48

Ø 3

2M

10

20

2035

55

Ø 2

617

2519

6,4

6,4

2519

( coo

ling

circu

it - c

ente

r )

Ø 2

0

Ø 2

6M

10

34,5

( coo

ling

circu

it - c

ente

r )( c

oolin

g cir

cuit

- cen

ter )

41,5

17

6

8

8

1111

2536

3,2

Ø 1

4

Ø 1

6,5

M 8

25

14

2014

27.04.2011 Blatt 4/31



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Meusburger bores patern / Ø 30 - Ø 42

36

3647

83

Ø 4

8M

16

Ø 4

218

3426

6,4Ø 42 / M 16

( coo

ling

circu

it - c

ente

r )66

Ø 30 / M 12

Ø 3

6M

12

24

2439

63

Ø 3

018

3225

6,4

( coo

ling

circu

it - c

ente

r )

48

10

10

27.04.2011 Blatt 5/31



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44

4459

103

Ø 54 / M 20

Ø 6

0M

20

Ø 5

422

4332

10,4

( coo

ling

circu

it - c

ente

r )82

12

Meusburger bores patern / Ø 54

27.04.2011 Blatt 6/31



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flame cutting

l

bB

LS

allowance and tolerance

S = thickness

Z

Z Y

Y

Y

400

600

600

B / L S

140

140

140

140

140

140

6,0 - 2,0 1730231123128,0 - 2,0

7,0 - 2,0

9,0 - 2,0

8,0 - 2,0

10,0 - 3,0

Zug. B/L Mat.Tol. B/Lb / l Zug. b/lmax. 200 Tol. b/l

Y 1,0 / 100

Z 0,2 / 100

R2 min.

27.04.2011 Blatt 7/31



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bores pattern - special

d1

d1

Ø 20

Ø 26

Ø 30

Ø 42

Ø 54

Ø 66

Ø 80

Ø 26

Ø 32

Ø 36

Ø 48

Ø 60

Ø 72

Ø 86

6,4 96

136

156

196

216

296

10,4

d2 t2t1

d2+0,4+0,8

t1t2

d1

27.04.2011 Blatt 8/31



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threads

metric threads imperial threads (inches)pitch in

d2

t1 t2

t4

d3

d4d1

d1 mmpitch in

mmd2 t1 t2 d3 d4 t4 d1 pitch d2

M 3 0,50 2,5 6 10 3,5 6,5 3,5 G 1/8" 28G/" 0,91 8,70M 4 0,70 3,3 8 12 4,5 8,0 4,5 G 1/4" 19G/" 1,34 11,60M 5 0,80 4,2 10 14 5,5 9,5 6,0 G 3/8" 19G/" 1,34 15,00M 6 1,00 5,0 11 15 6,6 11,0 7,0 G 1/2" 14G/" 1,81 19,00M 8 1,25 6,8 14 20 9,0 15,0 9,0 G 3/4" 14G/" 1,81 24,25M10 1,50 8,5 19 25 11,0 18,0 11,0 G 7/8" 14G/" 1,81 28,00M12 1,75 10,2 25 32 14,0 20,0 13,0 G 1" 11G/" 2,31 30,00M14 2,00 12,0 25 32 16,0 24,0 15,0 G 11/4" 11G/" 2,31 39,00M16 2,00 14,0 28 34 18,0 26,0 17,0 G 11/2" 11G/" 2,31 45,00M18 2,50 15,5 32 40 20,0 29,0 19,5M20 2,50 17,5 33 42 22,0 32,0 21,5M22 2,50 19,5 37 48 24,0 35,0 23,5M24 3,00 21,0 38 52 26,0 38,0 25,5M27 3,00 24,0 46 60 29,0 42,0 28,5M30 3,50 26,5 55 70 32,0 48,0 32,0M36 4,00 32,0 65 85 39,0 57,0 38,0M42 4,50 37,5 75 95 45,0 66,0 44,0M48 5,00 43,0 85 110 52,0 76,0 50,0

fine threadsd2 d2 d1 d2

M 4x0,5 3,5 M 16x1 15,0 M 30x2 28,0M 5x0,5 4,5 M 16x1,5 14,5 M 32x1,5 30,5M 6x0,5 5,5 M 18x1,5 16,5 M 33x2 31,0M 6x0,75 5,2 M 20x1,5 18,5 M 34x1,5 32,5M 8x0,5 7,5 M 22x1 21,0 M 35x1,5 33,5M 8x0,75 7,2 M 22x1,5 20,5 M 36x1,5 34,5M 8x1 7,0 M 24x1 23,0 M 36x2 34,0M 10x1 9,0 M 24x1,5 22,5 M 38x1,5 36,5M 10x1,25 8,8 M 24x2 22,0 M 40x1,5 38,5M 10x1,5 8,5 M 26x1,5 24,5 M 42x1,5 40,5M 12x1 11,0 M 27x1,5 25,5 M 42x2 40,0M 12x1,25 10,8 M 27x2 25,0 M 48x2 46,0M 12x1,5 10,5 M 28x1,5 26,5 M 48x3 45,0M 14x1 13,0 M 30x1 29,0 M 50x1,5 48,5M 14x1,5 12,5 M 30x1,5 28,5 M 52x2 50,0

d1 d1

27.04.2011 Blatt 9/31



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eye bolt

If plate weight > 800 kgprovide threads for eye bolts!

l1

l1

d1

d1

b4

E1272

E1274

d2

l3

< 90°

d1 d2 l1 max. kg max. kg max. kg max. kg M 10 25 15 1000 400 800 560 M 12 30 18 2000 750 1500 1000 M 16 35 24 4000 1500 3000 2100 M 20 40 30 6000 2300 4600 3200 M 24 48 36 8000 3200 6400 4500 M 30 60 45 12000 4500 9000 6300 M 36 75 54 16000 7000 14000 9800

< 90°

d

d1 b4 l1 l3 max. kg max. kg max. kg max. kg M 10 29 17 33 900 450 900 630 M 12 35 21 51 1200 600 1200 840 M 16 38 25 47 2600 1300 2600 1820 M 20 35 33 56 4000 2000 4000 2800 M 24 40 40 68 7000 3500 7000 4900 M 30 50 50 93 10000 5000 10000 7000

27.04.2011 Blatt 10/31



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top lock

R 10

b

0.2

= =a +0

.015

+0.0

05

+0.2 0

+0.1 0

l

c

t

M

pocket

take note ofclearance “c”

type

E1304

l

E 1304/34

E 1304/40

E 1304/50

E 1304/64

E 1304/72

18

22

30

40

52

34

40

50

64

72

10/18

12/22

15/30

18/40

20/46

M 4

M 5

M 6

M 8

M 8

22

26

34

42

48

7

9

13

17

19

b t M a c

27.04.2011 Blatt 11/31



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roughing

R

l

b b

corner radius / depthR t

17,5 -100 26

b / l

-150

pocket milled with insert cutters

bottom radius r = 3 mm - 6 mm depending on the tool used

< 100/100< 300/300

33 -210

max. t

Avoid max. depth if possible (higher machining costs) !

--240-300> 300/300

t

r

for complex forms:provide:- pre-work drawing- 2D-data: DXF, DWG- 3D-data: Parasolid, STEP

-2-3

-1-1,5

t -1-1,5

-2 -3-2 -3

27.04.2011 Blatt 12/31



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finishing

pocketb / l

200

400

600

600

Tol. b / l Tol. t+0,04 +0

- 0,02

+0- 0,04

+0,05

+0,06

+0,07

+0,01

+0,01

+0,01

+0,01

corner radius / depthmin. corner radius (R) bottom radius (r)std. F 53 ( t )depth ( t )

4 < 355 < 456 < 558 < 80

1050< 9012

0, 1, 2

0, 1, 2, 4

0, 1, 2, 4, 660< 1001680< 10520100< 12525< 15030< 20035< 250

Avoid max. depth if possible (higher machining costs) !

pocket for top lockTol. l Tol. t+0,2 +0,1

0 0

Tol. b+0,015+0,005

R

l

b b

Clearance in the angles

l

b

t

tr

In case of a small radii the clearances are drilled deeper than the pocket bottom.

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interlock

l

b

cylindric pocket

+0,02 0

+0,0

2 0

+0,0

2 0

R

t

corner radius / depth

4 < 256 < 35

< 45 8

0, 1, 20, 1, 2, 4

min. corner radius (R) bottom radius (r)depth ( t )

27.04.2011 Blatt 14/31



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interlockpocket with one inclined surface

lt

b

w

l1l1

R

corner radius / depth

variable4 < 256 < 35

< 45 8

0, 1, 20, 1, 2, 4

+0.02- 0.02

+0.02- 0.02

+0.02 0

+0.0

2 0

0 -0,0

2

A0,03/100 A

min. corner radius (R) bottom radius (r)depth ( t ) angle (w)

27.04.2011 Blatt 15/31



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interlock

Depending on production time and costs, angle radius will be machined with type 1 or 2.

t

8 10 12,516 20 25 28 35

< 70< 100

< 125< 150< 180< 230< 300

0, 1, 2, 4

0, 1, 2, 4, 6

10< 50 < 70< 100< 120

0, 1, 20, 1, 2, 4

0, 1, 2, 4, 6

3, 5, 10, 15, 203, 5, 10

3, 53

w

+0.04 0

A

0,03/100 A

Type 1: pocket - conical HS-tool

Type 2: pocket - line milling

variable



b

l

R - type 1 R - type 2

h7

h7

27.04.2011 Blatt 16/31



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interlock

pocket - conical HS-tool

Clearance recommended but not necessary!

b

w

l l

tR

clearance

pocket - line milling

8 10 12,516 20 25 28 35

< 70 < 100

< 125 < 150< 180< 230< 300

0, 1, 2, 4

0, 1, 2, 4, 6

variable

min. corner radius (R) bottom radius (r)depth ( t )10< 50

< 70< 100< 120

0, 1, 20, 1, 2, 4

0, 1, 2, 4, 6

angle (w)


3, 5, 10, 15, 203, 5, 10

3, 53

+0.02 0

+0.02 0

+0.04 0

+0.0

2 0 A

0,03/100 A

27.04.2011 Blatt 17/31



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inclined pin

d tol. d

Ø 10 +/-0,2 5° - 30°

Ø 12

Ø 14

Ø 16

Ø 18

Ø 20

Ø 22

Ø 24

Ø 30

Ø 40

pos. tol. angle

max.2 x d

d

+0,015- 0+0,018- 0

+0,021- 0

+0,025- 0

dd

E1034

E1032

27.04.2011 Blatt 18/31



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retainer for inclined pin

Position and angle to be selected.

pocket

R -0,2

+0,03+0,01

+0,0

3+0

,01

+0,0

5 0

0

b1

t

l1

b

M

l

d1

E3060

b l t b1 l1 MTyp

E 3060/10E 3060/12E 3060/14E 3060/16E 3060/18E 3060/20E 3060/22E 3060/24E 3060/30

263034384246505262

40

44525456626674

182428323638424452

8,51012141618202224

242628343638424452

M 6

M 8

M10

R

10

12

16

27.04.2011 Blatt 19/31



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slide

a

bE 3116E 3118

t3

t

a t3

11 3

12 2

15 3

19 4

24

+0,015 0

+0,015 0

0 -0,0

2

+0,0

2 0

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t2

Md22x

45°

t1 +1- 1

+0,2 0

+0,2

0

d1+0

,05

- 0,0

2

cooling circuit

standard cooling circuits and counter boresExample:

6 8

10

19

22

24

18d2

M 8x0,75M10x1R1/8”M14x1,5R1/4”M14x1,5R1/4”M16x1,5R3/8”

M t2d1

Feasible diameters and depths

Two-axis inclined holes can also be bored without problems!

Standard - machining from two sides!(machining for heat cartridge from one side)

560 860 760 560 560 760 7601360 9601360 960 96013601360 960136013601360156014601360136015601160136014601360156013601560

4 5 6 6,1 6,55 7 7,5 8,05 8,25 8,5 9 9,5 9,5510,0510,110,21111,211,512,0512,212,5512,712,85131414,21515,8516

t1 max.d11560116011601160116015601360146015601160156011601560116015601560116015601160

16,0516,2516,3217,217,61818,251920,0520,252222,12424,22526283032

t1 max.d1

27.04.2011 Blatt 21/31



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O-ring seals - counterbore

O-ring sealcounterbore

E 2130/ 7,5 x1,5E 2130/ 8 x1,5E 2130/ 9,8 x1,5E 2130/ 10 x2E 2130/ 10 x2,4E 2130/ 11,8x2,4E 2130/ 12 x2E 2130/ 13,9x2,4E 2130/ 15,3x2,4E 2130/ 17,5x2,4E 2130/ 19,3x2,4E 2130/ 21,3x2,4E 2130/ 23,3x2,4E 2130/ 25,3x2,4E 2130/ 27,3x2,4E 2130/ 28 x3E 2130/ 30,2x3E 2130/ 32,2x3E 2130/ 34,2x3E 2130/ 35 x2,5E 2130/ 36 x2E 2130/ 36 x3

D1 D2 T d1 d2 d47,07,59,3

11,0

13,214,516,818,520,522,524,526,527,029,331,333,3

35,0

1,21,21,21,61,91,91,61,91,91,91,91,91,91,91,92,42,42,42,42,01,62,4

7,58,09,8

10,010,011,812,013,915,317,519,321,323,325,327,328,030,232,234,235,036,036,0

1,51,51,52,02,42,42,02,42,42,42,42,42,42,42,43,03,03,03,02,52,03,0

10,511,012,814,014,816,616,018,720,122,324,126,128,130,132,134,036,238,240,240,040,042,0

11,012,515,5

17,3

19,520,823,024,826,828,830,832,835,037,039,041,0

43,0

d1d2

d4

D 0-0,1 +0

,05

0

+0,1 0

1D2

T

27.04.2011 Blatt 22/31



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2 guiding bores4 guiding bores

Postition and number of guiding bores to be selected.Tolerance for the position of bores +/- 0,01.

t3

d3d1d2

ejector set - guiding

H7d1

H7d1 +0

,3+0

,1d2

H7d2

E 1100E 1105

E 1325E 1330 E 1144E 1120

E 1125

d1 d1 d1d3 d3 d3t3 t3 t3d2

+0,020+0,008

+0,020+0,008

+0,020+0,008+0,022+0,010

+0,022+0,010

+0,022+0,010

+0,026+0,012

+0,018+0,006

+0,018+0,006

+0,018+0,006Ø 20

Ø 26

Ø 30

Ø 42

Ø 54

Ø 12

Ø 18

Ø 24

Ø 30

6,4 6,46,4

10.4

Ø 26

Ø 34

Ø 42

Ø 50

Ø 22

Ø 30

Ø 38

Ø 46

d1 d3 t3d2

+0,020+0,008+0,022+0,010

+0,018+0,006 Ø 12

Ø 18

Ø 24

Ø 30

6,4Ø 26

Ø 34

Ø 42

Ø 50

Ø 22

Ø 30

Ø 38

Ø 46

Ø 18

Ø 20

Ø 22

Ø 28

Ø 32

Ø 34

Ø 42

Ø 14

Ø 16

Ø 18

Ø 24

Ø 28

Ø 30

Ø 38

Ø 26

Ø 32

Ø 36

Ø 48

Ø 60

27.04.2011 Blatt 23/31



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ejector set - thread insert

d1 d3 b1 l3

Ø 30

Ø 40

46

56

34

46

6

6

b1

d1+1+2

+0.5

+1

+0.2+0.4

d1H7

d3

R10

l3 0+0.02

d1E1515

27.04.2011 Blatt 24/31



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chamfers

l

a

45°

recommended chamfer sizes: 11,5234568

chamfer sizes / standard

F / P-plates and risers

l

396

596

> 596

1,0

1,4

1,8

1,2

1,6

2,0

a min. a max.

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anti-twist protection

d Y1 X Y Ra Rb depth d Y1 X Y R1 R2 depth1,1 0,50 5,0 2,50 1,0 1,5 1,2

depth +0,05

X

d

R1

R2

Y1 +

0,02

Y

6,1 3,00 16,0 9,50 2,5 3,0 5,01,2 0,55 5,0 2,55 1,0 1,5 1,2 6,3 3,10 16,0 9,60 2,5 3,0 5,01,3 0,60 5,0 2,60 1,0 1,6 1,2 6,6 3,25 16,0 9,75 2,5 3,0 5,01,4 0,65 5,0 2,65 1,0 1,6 1,5 7,1 3,50 16,0 10,00 2,5 3,0 5,01,5 0,70 5,0 2,70 1,0 1,6 1,5 7,6 3,75 16,0 10,25 2,5 3,0 5,01,6 0,75 5,0 2,75 1,0 1,6 1,5 8,1 4,00 17,0 11,50 2,5 3,5 5,01,7 0,80 5,0 2,80 1,0 1,6 1,5 8,3 4,10 17,0 11,60 2,5 3,5 5,01,8 0,85 5,0 2,85 1,0 1,6 1,5 8,6 4,25 17,0 11,75 2,5 3,5 5,01,9 0,90 5,0 2,90 1,0 1,6 1,5 9,1 4,50 17,0 12,00 2,5 3,5 5,02,0 0,95 5,0 2,95 1,0 1,6 1,5 10,1 5,00 18,0 13,50 2,5 4,0 5,02,1 1,00 6,0 3,50 1,0 2,0 2,0 10,3 5,10 18,0 13,60 2,5 4,0 5,02,3 1,10 6,0 3,60 1,0 2,0 2,0 10,6 5,25 18,0 13,75 2,5 4,0 5,02,6 1,25 7,0 4,25 1,0 2,5 2,0 11,1 5,50 18,0 14,00 2,5 4,0 5,02,8 1,35 7,0 4,35 1,0 2,5 2,0 12,1 6,00 20,0 16,50 3,0 5,5 7,03,1 1,50 9,0 5,00 1,5 3,0 3,0 12,1 6,00 22,0 16,50 3,0 5,5 7,03,3 1,60 9,0 5,10 1,5 3,0 3,0 12,3 6,10 20,0 16,60 3,0 5,5 7,03,6 1,75 10,0 5,75 1,5 4,0 3,0 12,3 6,10 22,0 16,60 3,0 5,5 7,03,8 1,85 10,0 5,85 1,5 4,0 3,0 12,6 6,25 20,0 16,75 3,0 5,5 7,04,1 2,00 10,0 6,50 1,5 4,0 3,0 12,6 6,25 22,0 16,75 3,0 5,5 7,04,3 2,10 10,0 6,60 1,5 4,0 3,0 13,1 6,50 20,0 16,50 3,0 6,5 7,04,6 2,25 10,0 6,75 1,5 4,0 3,0 14,1 7,00 24,0 18,50 3,0 6,5 7,04,8 2,35 10,0 6,85 1,5 4,0 3,0 14,6 7,25 24,0 18,75 3,0 6,5 7,05,1 2,50 12,0 8,00 1,5 5,5 3,0 16,1 8,00 23,0 19,50 3,5 6,5 7,05,3 2,60 12,0 8,10 1,5 5,5 3,0 18,1 9,00 25,0 21,50 4,2 7,3 7,05,6 2,75 12,0 8,25 1,5 5,5 3,0 20,1 10,00 27,0 23,50 4,2 9,3 8,0

25,1 12,50 33,0 29,00 6,0 12,3 10,032,1 16,00 41,0 36,50 8,5 17,0 10,0

= ejector diameter +0,1

27.04.2011 Blatt 26/31



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distortion

Machining with little distortion!

Distortion possible due to the following machining!

Take special care of distorsion with steel type 2085, open outlines or heat-treatment e.g. nitriding!

27.04.2011 Blatt 27/31



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strength: E 1405 330 N/mm²E 1425 600 N/mm²

thickness: As per drawing(standard 6 or 8 mm)

machining: 3D as STEP or Parasolid prefered2D as DXF or DWG

time of delivery: 8 working days

price: on inquiry

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roughing 3D

data import

stress-relieving heattreatment

machining

WKF - from VISI, Parasolid, Stepdirect interfaces (Catia V4, V5, Unigraphics, Pro-E)

any plate which has been massively roughed will be stress-relieved again.After this process the reference surface will be finished and the 2D machining achieved (e.g. holes, threads, pockets etc.)

data export we supply the customers with STL files for subsequent machining.

allowance to be selected:smallest possible tool Ø:angle radius (pocket bottom):

Support areas for subsequent machining to customer specifications.

standard 1 - 2 mm35 mm (R 17.5)R 3 - R 6

max. size 1.100 mm1.600 mm2.500 kg

width:length:weight:for exceeding dimensions, the feasibility will be determined accordingly(clamping, weight, job execution).

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Stress-relieving heat-treatment

heating upperiod hold period cooling period

4 hours 6 hours 14 hours = 35°C per hour

Heat-treatment graphic

capacity: 100 tons per day

Any steel which we machine is stress-relieved with great care.Thanks to a long maintaining of the temperature and a slow coolingof the oven at the rate of 35°C/h we obtain best results in terms ofstress-free material.

10 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2420

100

200

300

400

500

600

°C

h

700

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Meusburger Georg GmbH & Co KG | Formaufbauten | Kesselstr. 42 | A-6960 Wolfurt

T 00 43 (0) 55 74 / 67 06-0 | F -11 | [email protected] | www.meusburger.com

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