Engineering

Engineering generally falls into two groups:

Direct engineering
Reverse engineering

OLDENG engineering company provides services in both.

Reverse engineering means that you have the production sample and need to obtain the technology allowing reproduction of this sample with preserved performance and at minimum cost.

OLDENG company uses the following algorithm when developing a project using reverse engineering:

1) Production sample is put on the plate-measuring machine to obtain a digital point cloud.

2) Obtained 3D model of the sample by means of Surface Modelling software.

3) A project of technological tooling is made by means of Solid Modelling software:

press mould
injection mould
chill mould
press die

Then mould cavities are formed using a digital 3D model.

4) Depending on required number of production pieces per unit time, necessary tooling performance value, number of cavities and dimensions are calculated.

5) Depending on overall dimensions of the technological tooling, mass of the mouldings cluster and material of the sample, the technological equipment is selected:

injection molding machine
die casting machine
gravity vasting machine
hydraulic press
mechanical press

6) Main technological characteristics of the equipment are calculated and selected: clamping force, injection volume, overall dimensions of the plates, pressure, heating and cooling temperatures.

7) Based on these calculations, final selection of the technological equipment typical size is made.

Example: a high-pressure mould machine for metal materials with a cold pressing chamber, a clamping force of 200 tons and a mass of cast metal of 1.5 kg; or an injection mould machine with a clamping force of 80 tons and an injection volume of 112 cm3; or a hydraulic press for rubber materials with a clamping force of 160 tons and heating plates.

8) Necessary auxiliary equipment is selected and calculated.

Example: an anthropomorphic robot with calculated rotation radius, tilting angle, arm stretch, load applied to the arm, and grip type; filling, lubricating, pulling manipulatorswith calculated movements, volumes, nozzle and grip types. For cooling equipment (for press moulds, injection moulds and other types of tooling) refrigerators (chillers) of sufficient power are selected. Depending on the requirements of technological process, a single refrigerator (chiller) can maintain both technological equipment and tooling. In other scenario separate low-power chillers are used for cooling technological equipment and tooling. Or, one large chiller can cool several units of technological equipment simultaneously. Thermostat (thermostatic control system) is also calculated and selected, which ensures heating of technological equipment to safe operating modes avoiding "heat stroke" and providing high geometric repeatability, high density and low porosity of obtained product. Furnaces: electric, gas, resistor furnaces,HFC furnaces for thermosetting materials.

9) Equipment for separation and removal of gating systems(butt-ends, washers, feeders) is selected and calculated.

Example: hydraulic press with a pressing force of 20-25 tons and a shearing die.Grinder of a rotary or auger type for processing gating systems. When selecting a grinder, size of its loading door (must exceed size of the gating systems) and performance in kilograms/hour are calculated.

10) In case more deep processing of gating systems is required, a granulator is selected.

11) Technological tooling is produced: mould, injection mould, press mould, chill mould, press die, fixture.

12) Technological equipment is placed along the technological chain in the production room.

13) Plans of understructures and necessary communications are drawn: energy supply, water supply, compressed air supply.

14) Manufactured technological equipment and technological tooling are mounted, supervised installation is performed.

15) Optimal technological modes and parameters are set: temperature, holding period, mass.

16) Optimal technological programs and technological charts are developed and saved.

17) Advisory service for workers, set-up specialists and technologists are provided.

18) Technological system effectively operates based on set parameters and produces the required number of production pieces per unit time in accordance with initial sample and at a minimum cost.

Direct engineering means that you want to implement an idea or create a new product with specified properties.

1) Parameters, technical and ergonomic properties of the future product are set.

2) A 3D model is created.

3) A solid-state prototype (additive technology) is manufactured on the prototyping device.

4) Solid-state prototypes are used to check the assemble ability, ergonomics and cooling channels of internal cavities. According to the verification results, necessary changes and corrections are applied to the 3D model.

5) Based on the adjusted 3D models, control programs for CNC machines are developed.

6) Based on the control programs for CNC machines, technological tooling is manufactured.

Example: a press mould, an injection mould, a chill mould or a press die.

7) Depending on required number of production pieces per unit time, necessary tooling performance value, number of cavities and dimensions are calculated.

8) Depending on overall dimensions of the technological tooling, mass of the mouldings cluster and material of the sample, the technological equipment is selected:

injection molding machine
die casting machine
gravity casting machine
hydraulic press
mechanical press

9) Main technological characteristics of the equipment are calculated and selected: clamping force, injection volume, overall dimensions of the plates, pressure, heating and cooling temperatures.

10) Based on these calculations, final selection of the technological equipment typical size is made.

11) Necessary auxiliary equipment is selected and calculated.

Example: an anthropomorphic robot with calculated rotation radius, tilting angle, arm stretch, load applied to the arm, and grip type; filling, lubricating, pulling manipulators with calculated movements, volumes, nozzle and grip types. For cooling equipment (for press moulds, injection moulds and other types of tooling) refrigerators (chillers) of sufficient power are selected. Depending on the requirements of technological process, a single refrigerator (chiller) can maintain both technological equipment and tooling. In other scenario separate low-power chillers are used for cooling technological equipment and tooling. Or, one large chiller can cool several units of technological equipment simultaneously. Thermostat (thermostatic control system) is also calculated and selected, which ensures heating of technological equipment to safe operating modes avoiding "heat stroke" and providing high geometric repeatability, high density and low porosity of obtained product. Furnaces: electric, gas, resistor furnaces, HFC furnaces for thermosetting materials.

12) Equipment for separation and removal of gating systems(butt-ends, washers, feeders) is selected and calculated.

13) In case more deep processing of gating systems is required, a granulator is selected.

14) Technological equipment is placed along the technological chain in the production room.

15) Plans of understructures and necessary communications are drawn: energy supply, water supply, compressed air supply.

16) Manufactured technological equipment and technological tooling are mounted, supervised installation is performed.

17) Optimal technological modes and parameters are set: temperature, holding period, mass.

18) Optimal technological programs and technological charts are developed and saved.

19) Advisory service for workers, set-up specialists and technologists are provided.

20) Technological system effectively operates based on set initial parameters and produces the required number of production pieces per unit time at a minimum cost.

21) An alternative technology is selected if necessary.