AN innovative system designed by Witte Bleckede, represented by R&M Mauer , speeds up modelling, is more flexible and saves material cost.
Development of the completely new lightweight modelling system leads to economical advantages in the process of product development - for service providers and automobile manufacturers, aerospace industry and boat builders alike.
The Alufix Modelling System concept is suitable for models and moulds such as data control models (DCMs), cubings, design models, and mock-ups.
According to the manufacturers, disadvantages of conventional model-making using solid aluminium blocks and castings, or blocks of epoxy resin, are avoided completely.
The Alufix Modelling System fulfills requirements specific to different kinds of models and moulds, extending and improving existing concepts.
The basic idea arose from careful observation of outer skin and sub structure of models, and the search for proven elements to incorporate into their design.
Witte's new substructure is made of thin aluminium profiles and assembled in boxlike groups with adjustable set up heights.
For CNC cutting of horizontal and vertical ribs out of metal sheets to simulate the workpiece surface, existing CAD design data of the part is simply entered into Alufix design software and modified for machining.
These metal sheets are machined with fitted grid bores as used in Alufix or in other fixturing systems. The ribs are therefore basically new standardised Alufix elements which can, for instance, be integrated into Alufix modular fixturing system.
Witte's Alufix modular fixturing system stems from its experience during development and manufacture of modular workpiece clamping and fixturing systems in aluminium.
The Alufix system comprises a multitude of high-tensile standardised aluminium elements and enables fast and flexible assembly of reusable or one-off fixtures for measuring.
With the help of this system only a fifth of the time is necessary compared with conventional, fixture-building methods.
For more than twenty years the trendsetters regarding quality management, namely the automobile industry, have been using the Witte system.
The time-saving advantage is becoming more relevant as cost effectiveness of expensive 3D coordinate measuring machines is increasingly linked directly to production expense.
Until now it has not been possible to transfer this time and cost advantage to models and moulds. However, after successful technical realisation of the Alufix modular concept specifically for model making, that has changed.
The model's outer skin is made by placing wire mesh on to the ribcage which is mounted to a base plate. This mesh is then covered liberally with self-hardening compound resin.
The layer thickness needs to be a maximum of 10mm more than the actual zero dimension to be achieved, leaving enough room and clearance for milling. The advantages of this concept are convincing:
* Low material costs.
* Good machinability of material.
* Shorter machining times due to considerably shorter milling processes.
* Lower tooling costs.
* Fast corrections or optimisation of surface by adding paste material and remilling.
Manufacture of metal sheets with Alufix grid also enables design of ribs at any height and therefore full-sized models can also be built using Witte modelling system.
This new modelling system combines the advantages of lightweight building with advantages from consistent use of Alufix grid and fixturing system:
* Model-making can be integrated into standardized measuring fixtures and tooling.
* Single models can be connected to a frame and if required can be joined together to form a complete model.
* Design of a DCM data control model is made easier.
* Models can often be transported without a crane and there is no need for reinforced foundations.
Special Alufix adjusting elements cater for fine adjustment and secure fixation, whereby the models can be adusted not only in X, Y and Z but can also be angled and rotated.
The use of considerably less material and not least the high savings in weight make the Witte system a considerably flexible and economical alternative.