Complexity simplified through Metal injection molding.
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Transcript of Complexity simplified through Metal injection molding.
Innovative Metal Working
Process- MIM Compound... Inject… Sinter… Use.
Indo-MIM Confidential
Conventional Method:
Counter hole drill & Reaming
Thread Tapping
Cylindrical tube machined to convert in to a blank
profile
Gear Profile making using Gear Shaper Machine
Slot Cutting
Conventional Method of metal working
Chamfer on the legs & ID
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What if we can do this ?? What, If We can do this??
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Complexity Simplified through - MIM
Raw Material
Machining
Gear Forming
Slot cutting
Counter hole drilling
Finished Part
MIM
Simplify the complex shape making process to one single operation of
MIM
Thread Tapping
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Contents
• What is MIM?
• WHY MIM?
•What is CIM?
• Why INDO-MIM?
• Our Customers
• Case Studies
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METAL INJECTION MOLDING MIM is .…
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Introduction
• Marriage between Powder Metallurgy and Plastic Injection Molding – (Metal Injection Molding)
• The need for complex shaped parts in large volumes with short lead times triggered the MIM technology
• Defense industry was the mother of MIM. Other industries like Electronics, Consumer, Automotive use MIM extensively today
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4 SINTERING
• Inter particular welding
3 DE-BINDING
• Solvent • Thermal
2 MOLDING • Binders melt • Carries powder Into mold
1 COMPOUNDING
• Powders • Binders
Simplicity in complexity
MIM Process
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Fine metal powder less than 20µ particle size is blended with
thermoplastic and wax binders in precise amounts to form feedstock
Compounding
Feedstock is the input for molding the part
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Molding
Feedstock is injected into a metal mold to form the net shape
Molding machine Molding Tool Green parts
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Debinding
Primary binders are removed from the molded part
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Sintering
The parts are slowly heated in a protective atmosphere to drive out the remaining binders. Once the binders are evaporated, the part is
heated to high temperature where the void space between the particles is eliminated as the particles fuse together
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Challenge is in predicting the shrinkage to achieve final dimensions accurately first time right
Molded part
Sintered part
From Powders to Net shape
Sintering shrinkage
~ 20%
Feedstock
Binder
Metal powder
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What happens during sintering?
Scanned Electron Micrographs of MIM parts at various manufacturing stages
Phase 1
Phase 2
Phase 3
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WHY MIM ?
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Metal Injection molding
High
Investment casting
Prod.Qty
6 10
Complexity
5
4
10 Low Medium
Machining
Die Casting
10
10
3
Press and
Sinter
Low
Medium
High
MIM vs other manufacturing methods - Productivity
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Press and
sinter Un
it C
ost
Machining
Casting
MIM
Low Medium High
Complexity
MIM vs other manufacturing methods - Cost
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0 250 500 750 1000 1250 1500
P/M
MIM
Ultimate Tensile Strength, MPa
P/M MIM
Material Strength
MIM vs PM
MIM vs other manufacturing methods - Strength
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1090
1380
38
1040
1320
38
0
200
400
600
800
1000
1200
1400
1600
YS (MPa) UTS (MPa) Hardess (HRC)
MIM 4605(Fe2Ni0.4C)
En 19A
1090
1380
38
1040
1320
38
0
200
400
600
800
1000
1200
1400
1600
YS (MPa) UTS (MPa) Hardess (HRC)
MIM 4605(Fe2Ni0.4C)
En 19A
Material Strength similar to wrought material
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MIM Vs Traditional Metal Forming Process…
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Case hardened
steel
•MIM8620
•MIM9310
•MIM4600
Through hardened
steel
• MIM4650
• MIM4340
• MIM4140
• MIM52100
Stainless steel
• SS17-4Ph
• SS304 L
• SS420
• High Temp application
• SS440C
• SS310Nb
• SS310
• Corrosion resistant
• SS316L
• SS310Nb Magnetic Material
• Fe3Si
• SS430
• Fe-49Co-2V
Heavy/Super Alloys
• WHA1
• WHA2
• Inconel
• Nimonic90 Tool Steel • S7, M2, D2
Materials we offer…
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MIM is best at…
MIM
Threads
Calligraphy
Knurling Complicated
profiles
Angular holes
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MIM can be treated like any other wrought material
MIM
Machining
Grinding
Heat treatment
Surface treatments
Tumbling
Plating, Polishing
Welding
Sizing
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What is an ideal MIM part ?
MIM Weight limit <200gms
• Ideal 0.1 to 50gms
Annual Requirement from 50,000 to 20
Mil is possible
Length limit<200mm
• Ideal < 60mm
Wall thickness 0.5mm to 5mm
• If >5mm, coring is essential
Tolerances as per ISO 2768 (M) and
thumb rule of ±0.5% of nominal dimension
All the high melting point alloys are possible.
• (Materials like Brass, Aluminum, Magnesium is not MIM feasible)
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MIM fits everywhere
Medical
Power tools Sanitary Aerospace
Computer hardware Electronic connector Automotive Mobile phones
Locks
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Ceramic Injection Molding (CIM)
Powder to Finished Parts
Aluminum Oxide (Alumina) 96% pure alumina:
• For parts that require good wear and corrosion resistance, such as in electrically insulating bodies and the vacuum industry
• Maximum temperature of use: 1600° C
Aluminum Oxide (Alumina) 99.8% pure alumina:
• For parts that require good wear and corrosion resistance, such as in Thread guide, Spark plugs Insulators, electrically insulating bodies and the vacuum industry
• Maximum temperature of use: 1600° C
ZTA and Zirconium Oxide :
• For parts that require good wear and Bio compatible such as Medical device and implants
CIM Materials
Medical/ Dental applications
• Orthodontic brackets
• Dental Implants
• Prosthetic replacements
• Abutments
• Endoscopic tools
• Tweezers
Textile Industry
• Wire guides
• Textile Thread Guides
• Twist Stopper
Watches/ Jewelery
• Precision watch gears
• Watchcases
Communication
• Ferrules
• Optical Sleeves
• Soft Magnetic components
Exhaust system Components
• Oxygen Sensor components
CIM Applications
Metallurgy
• Ceramic Casting cores
Automotive Components
• Valve components
• Turbocharger rotors
• Swirl chamber for high power
• turbocharged Diesel Engines
• Radial rotors with integrated ceramic shaft
• Airbag components
• Gear Wheel for fuel pumps
Electrical Components
• Electrical components for automotive exhaust
• Microwave dielectric components
Home appliance and office equipments
• Injector for precolators
• Paper Mill grinding gears
• Inkjet printheads
• Back cover of mobile phones
CIM Applications
Engine Components/ Engineering
• Water Pump seals
• Nozzles, guides, gear wheels, screw threads
• Stators, Precision dispensing nozzles
• Sensor covers and sensor tubes
• Tooth belt wheel
• Bearings
• Seals
• Scissors
• Micro Electrodes for ultrasonic welding
• Drill Bit
CIM Applications
WHY Indo-MIM
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Indo-MIM Fast Facts
2011 2012 2010 2011 1997
Start of Joint
venture
Independent
company
Starting of second
plant
Aerospace
division
Medical facility,
Titanium Injection,
Ceramic Injection
molding
Starting of
Investment casting
World’s Largest
MIM company
2006 2001
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Our Markets
26% 20% 2% 30% 22%
Industrial Medical Defense Auto Consumer
Manufacturing Facilities
Gowri IC
11000 Sq M
Short to medium run
Engineering
Admin
22000 Sq M facility
Tool room, plating shop
$8 Ml Green field project
High volume
Aerospace
Medical
At Tirupathi, 250 kms from Bangalore
3500 Sq M
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Additional 10000 sq.M being added
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Type Current Quantity (numbers)
Being added in next six months (numbers)
Molding Machines 95 22
Sintering Furnaces – Batch 14 8
Sintering Furnaces – Continuous 3 1
Milling Machines 17 3
EDM’s (Mitsubishi -11) (Makino -02)
13 2
WEDM’s 4 1
Expansion Plan
Integrated MIM Manufacturing
Design, Engg&
Tooling
Quality system
• ISO 9001:2008
• ISO/TS 16949:2009
• ISO 13485: 2003
• ISO Class 8 Clean Room
•AS 9100 : 2009-01 Rev.C
Feedstock
Injection
Molding
Debinding and
Sintering
Secondary
operations
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CASE S t u d i e s
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Case study -1
Problem • Conventional machining
– more lead time
• More operations
• High rejections
• Less strength at welded features
• Burrs due to hole forming
• Welding of half circle profile to the cylinder
• Hole forming
Solution • Component made
in MIM
• Only one secondary operation
Results • Cost savings more than
40%
• Less lead time
• Increased customer sales
Product Application : Auto Slack Adjuster
Critical requirement : High wear resistant, less lead time,
increased productivity
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Case study -2
Problem
• To make multiple holes of 0.5mm dia.
• Inconsistency in hole dia.
• Longer lead times
• To meet the annual requirement of 200 K
Solution • Component made
in MIM
Results • O.5 mm dia
outlet holes achieved in as sintered condition
• 200 K can be achieved very easily
• 100% consistency in all the dimensions
Product Application : Fuel Injection Nozzle
Critical requirement : Out let holes of 0.5mm dia and corrosion
resistance
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Case study -3
Problem
• PM Process+ Machining operations
• Part size is big due to lower material strength
Solution • Redesigned the
part to smaller ,size ,weight and all the features by MIM process at lower cost
• No secondary operations
Results • Near net shape as
sintered
• Less lead time
• High volume
• Increased customer sales
Product Application : Control lever
Critical requirement : Reduce weight, costs and increase strength
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MIM integrates different operations…
Earlier method
• Stamping + Bar stock pins + Riveting of pins + Plating
MIM Method
• As-sintered + Plating
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Pictorial image of Tool Design
Market Segment Automotive Challenge Indo-MIM solution
Y junction hole cross section
Tool made with 6 slides for all the cross holes.
Engineering Milestones
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Market Segment Automotive Challenge Indo-MIM solution
12 slides in the tool and Part weight of 160
grams
Tool made with 12 slides in rotary axis and part successfully made in
MIM
Pictorial image of Tool Design
Engineering Milestones
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Our Customers – Automotive
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Our Customers – Consumer and Industrial
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Our Customers – Medical components
The word “simplicity” exists because of “complexity” So, don’t think that your design is complex. We are here to make it simple
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Indo-MIM Offices
Princeton, New Jersey
Stuttgart, Germany
Shanghai,China
Bangalore, India
Brasilia, Brazil
Taipei, Taiwan
Tokyo, Japan
Sales Offices
Headquarter
Planned office by FY 15
Contacts
MIM & Finishing Operations: #45[P], KIADB Industrial Area, Doddaballapur, Bangalore 561 203 Tel: +91 80 763 0533/ 763 0532 Fax: +91 80 2763 0532 Email: [email protected]
Headquarters & MIM Operations: No 45,(P) KIADB Industrial Area, Hoskote, Bangalore 562 114. Tel: +91 80 2204 8800/2797 1418/2797 1416 Fax: +91 80 2797 1624 Email:[email protected]
USA: 214, Carnegie Center Suite 104, Princeton, New Jersey 08540 Ph: 734-327-9842/734-327-9872/609-651-8238 Fax: 734-327-9873 E-mail : [email protected]
EUROPE: Indian Business Center, Oskar – Lapp Str.2 70565 Stuttgart-Vaihingen, Germany Tel: +49 173 65500242 / +49 173 65500243 Fax: +49 711 65500241 E-mail: [email protected]
IC Operations: Gowri Ventures Pvt.Ltd. Plot # 62B (Part II), APIIC Industrial Park, Gajulamandyam, Renigunta 517 520, AP Tel: 91. 9390845662/63/64 & 65 Email : [email protected]
CHINA : 11F Aurora Plaza, No. 99 Fu Cheng Road Pudong New Area 200120, Shanghai Tel: +86 (0) 21 6058-9206 Fax: +86 (0) 21 6058-9376 E-mail: [email protected]
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TAIWAN: 1F, No.436, Anji St., Zuoying Dist. Kaohsiung City 813, Taiwan (R.O.C) Ph: 886-6-2089488 Fax: 886-988664706 E-mail : [email protected]
JAPAN: Kotoku, Kameido 1-16 Tokyo, Japan, 136-8521 Tel: +81 03-3363-2271 Fax: +81-03-3683-6103 E-mail : [email protected]
THANK YOU
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