Development and Construction of a Device for Copper Chamfering

The diploma thesis briefly presents the company Elsta Mosdorfer and the Knill Gruppe group, whereby the companies within the organisation differ; the industries with which the company is engaged, and a specific topic or need that is faced daily. The diploma thesis describes the company Elsta Mosdorfer (Kaindorf) in more detail. The choice of topic for the diploma thesis was attempted to be linked to a problem faced on a daily basis and an idea was found which would facilitate and improve the processing of copper, which is transformed into desired shapes in tonnes annually and is also optimally processed through various other procedures.

Problem

The diploma thesis briefly presents the company Elsta Mosdorfer and the Knill Gruppe group, whereby the companies within the organisation differ; the industries with which the company is engaged, and a specific topic or need that is faced daily. The diploma thesis describes the company Elsta Mosdorfer (Kaindorf) in more detail. The company and the topic of the diploma thesis relate to the electrical field, which is the so-called division of the company.

Solution and Method

The choice of topic for the diploma thesis was attempted to be linked to a problem faced on a daily basis and an idea was found which would facilitate and improve the processing of copper, which is transformed into desired shapes in tonnes annually and is also optimally processed through various other procedures. Copper is one of the materials which conducts electrical energy best and is found in all electrical cabinets and transformer stations in their company. With the help of the Boschert CU-WK-2 device, copper of various dimensions is cold-pressed in the form of a die.

The machine is designed for efficient punching of copper bars and is equipped with CNC control with a 5-head AMADA tool system. Once the copper is processed, nuts with various metric threads (most commonly M6, M8 and M10) are then pressed into it. A problem arose when copper arrived from the supplier softer, as it would bend and consequently strike the edges of the processing surface, and in the worst case destroy the dies used in cold pressing.

During research, it was observed that in their company (Kaindorf) 200 tonnes of copper are processed annually, or 280 tonnes in total, and thus a need arose for a machine for chamfering copper 1×45*. The principle of the machine is very similar to the GARANT Volumec JT3150, but the difference lies in the processing table, the clamping principle and the processing tool. The processing surface is 1450×600 mm, with 2 pneumatic clamps attached to it, as the workpieces are between 200 and 2000 mm long.

With the help of Creo 7.0, the component parts of the entire machine were modelled, assembled in an assembly drawing and then a plan was made for the production of a prototype. The plans are made at a scale of 1:1, so that in the event of production there would be no inappropriate lengths or problems with assembly.