Mineral Casting RHENOCAST - Electromate Industrial Sales Limited

The SCHNEEBERGER product documentationLINEAR BEARINGSand Recirculating unitsMINIRAIL SLIDES POSITIONING SYSTEMSMONORAIL AUTOMATION IMAGE BROCHURE Special ComponentsSCHNEEBERGER COMPANIESSWITZERLANDW. Schneeberger AGSt. Urbanstrasse 124914 Roggwil/BEPhone +41 62 918 41 11Fax +41 62 918 41 00E-Mail:info-ch@schneeberger.comwww.schneeberger.comSALES DEPARTMENTAUSTRIAPhone +43 2 2387 2945Fax +43 2 2387 2983Mobile +43 67 6935 1035E-Mail:info-a@schneeberger.comISRAELPhone +972 9767 9499Fax +972 9767 3397Mobile +972 505 51 7920E-Mail:info-il@schneeberger.comGERMANYSchneeberger GmbHGräfenau, Postfach 7075339 Höfen/EnzPhone +49 7081 782 0Fax +49 7081 782 147E-Mail:info-d@schneeberger.comBELGIUM, THE NETHER-LANDS AND LUXEMBOURGPhone +31 4 3365 4532Fax +31 4 3365 3579Mobile +31 6 5326 3929E-Mail:info-nl@schneeberger.comKOREAPhone +82 2442 0971Fax +82 2442 2971Mobile +82 1 6202 0971E-Mail:info-k@schneeberger.comITALYSchneeberger S.p.A.Via S. Gottardo, 1021021 Angera VAPhone +39 0331 93 2010Fax +39 0331 93 1655E-Mail:info-i@schneeberger.comNORTH FRANCEPhone +32 6833 7773Fax +32 6833 3863Mobile +32 479 78 1870E-Mail:info-f@schneeberger.comPOLAND, SLOVAKIA ANDCZECHOSLOVAKIAPhone +42 05 4725 0333Fax +42 05 4725 0444Mobile +42 06 0278 4077E-Mail:info-cz@schneeberger.comUSASchneeberger Inc.11 DeAngelo DriveBedford, MA 01730Phone +1 781 271 0140Fax +1 781 275 4749E-Mail:info-usa@schneeberger.comSOUTH FRANCEPhone +33 4 7239 5223Fax +33 4 7239 5224Mobile +33 6 0941 6269E-Mail:info-f@schneeberger.comSPAIN AND PORTUGALPhone +34 6 4991 9740Fax +34 9 4687 0973Mobile +34 6 4991 9740E-Mail:info-es@schneeberger.comJAPANNippon Schneeberger KK3-23-12 Shimouma, Setagaya-kuTokyo 154-0002Phone +81 3 5779 7339Fax +81 3 3487 6010E-Mail:info-j@schneeberger.comGREAT BRITAINPhone +44 16 2582 7708Fax +44 16 2582 7780Mobile +44 77 8814 5645E-Mail:info-uk@schneeberger.com20.2116/-01/1104/e/2.2/SRO/EG/Printed in Switzerland. Subject to tecnical changesMineral Casting RHENOCAST ® –Module for creative solutions

Mineral casting RHENOCAST ® , a product of the SCHNEEBERGER-GroupFor many years, the nameSCHNEEBERGER has been synonymouswith modern linearguide technology used in a varietyof industrial equipment andmachines construction.With over 50 years experiencein the design and manufacture ofLinear Technology Products, theSCHNEEBERGER-Group hasconsistently introduced manyinnovative products and systemsolutions in the market.Our global presence with strongsales and support organisationsguarantees closeness to thecustomer in all major industrialeconomies. Comprehensive logisticscapabilities and localsupport, assures a close partnershipstarting at the projectplanning phase.Schaffhausen, SwitzerlandProduction facilityProduct line mineralcasting RHENOCAST ®Roggwil, SwitzerlandMain company domicileand production facility> Technology Know-howRHENOCAST ® has been manufacturing high quality mineralcastings since 1987. Since then, RHENOCAST ® hasproduced many innovative product solutions for a varietyof industries and applications related to machine building.Mineral castings replace metallic castings used for machinebases and other structural components. TodayRHENOCAST ® is a trade mark for pioneering mineralcasting technology, which – thanks to the outstandingproduct characteristics and benefits – is gaining more andmore global acceptance.Our extensive experience with mineral casting, and itsmany and diverse application possibilities, make us apowerful partner for machine and plant builders. Our customerand application support starts at the concept phase;thanks to FEM (Finite Element Analysis) we are able to simulatethe effects of dynamic and static loads without theneed of building a prototype. In addition, we can verify therequired characteristics of the cast component parts andthe overall thermal behavior.Thermal vertical deformationto 1/100 mm0.2170.1920.1490.1070.0640.021-0.021-0.064-0.107-0.149-0.192ZYXManufacturing Know-howMineral castings RHENOCAST ® are manufactured in ourSchaffhausen, Switzerland facility. Our experiencedemployees manufacture mineral castings under rigorousquality procedures, from the beginning of the process tothe final assembly, which assures consistent product quality.Our controlled process guarantees that complexmachine structures are produced to the specified geometricaltolerances every time.> Comprehensive Engineering Know-how from a single sourceThe integration of the mineral casting RHENOCAST ® product line with theSCHNEEBERGER linear technology has further enabled the Group to offer itscustomers unique technological advantages:• 1• The incorporation of the mineral casting and linear technology offer greatdesign flexibility and innovative system solutions.• The combination of both technologies produces economic and technicalbenefits.• Our experienced engineers can design complete, customer-specific, productsolutions by utilizing their extensive knowledge in both the mineral casting andlinear technologies.• As the customer, you benefit from a more efficient and seamless process, fromthe original concept, through production and to the delivery of the final product.• 2

The advantages of mineral casting RHENOCAST ® • 4Shaping and StrengthThe mineral casting process provides an exceptionaldegree of freedom with respect to the shape of the components.The specific characteristics of the materialand of the process result in a comparatively highstrength in conjunction with a significantly lower weight.Economical Dimensional AccuracyIn many instances RHENOCAST ® components are castto the final dimensions because practically no contractiontakes place during hardening. With this, furtherexpensive finishing processes can be eliminated.Integration of InfrastructureThe mineral casting process enables the simple integrationof the structure and additional componentssuch as guide-ways, threaded inserts and connectionsfor services, during the actual casting process.No CorrosionRHENOCAST ® components are resistant against oils,coolants and otherThe Manufacturing of Complex Machine StructuresWhat would be inconceivable with conventional processesbecomes possible with mineral casting: Severalcomponent parts can be assembled to form complexstructures by means of bonded joints.Greater vibration damping for longer tool service livesIn vibration damping, RHENOCAST ® achieves up to 10x better valuesthan steel or cast iron. Thanks to these characteristics, an extremelyhigh dynamic stability of the machine structure is obtained. The benefitsthat this has for machine tool builders and users are clear: betterquality of surface finish of the machined or ground components andlonger tool life leading to lower tooling costs.Good thermal stabilityMineral casting reacts very slowly to temperature changes because thethermal conductivity is significantly lower than metallic materials. Forthis reason short- term temperature changes have significantly lessinfluence on the dimensional accuracy of the machine tool. A betterthermal stability of a machine bed means the overall geometry of themachine is better maintained and, as a result, geometrical errors areminimised.ConclusionMineral casting RHENOCAST ® is not only an alternative to conventionalcast-iron or steel constructions, but in many instances the superiortechnology.It also has a major economic benefit: RHENOCAST ® components areup to 30% cheaper.PrecisionHighly precise reference or supporting surfaces areachieved by further grinding, forming or milling operations.As a result of this, many machine concepts canbe implemented elegantly and efficiently.> Characteristic material values of mineral casting RHENOCAST ®Density2.30 – 2.45 kg/dm3Modulus of elasticity40 – 45 kN/mm2Tensile strength15 – 20 N/mm2Compressive strength100 – 120 N/mm2Bending-tensile strength28 – 30 N/mm2Coefficient of linear expansion 11.5 – 14x10-6 K-1Thermal conductivity1.5 – 2 W/mKSpecific heat capacityca. 1.2 kJ/kgKLog. decrement 0.03 – 0.10Linear contraction after casting approx. 0.3 ‰• 3

The range of applications of mineral casting RHENOCAST ® • 6Mineral casting RHENOCAST ® is used in a variety of industries and applications suchas Semiconductor capital equipment, machine tool, medical equipment, metrologyequipment, automation systems and many other specialized applications. Its uniquematerial properties and design flexibility makes it ideal for complex structures unattainableby conventional metallic castings. Mineral castings can be weighing fromjust a few kilograms to well over 10 tons.Stands for Automatic Assembly MachinesFor the production of medical components, such as insulinsyringes, machines for the automation of assembly processesare required. These automatic assembly machinesare conceived and manufactured the customer’s specification.The illustrated stand is manufactured out of two mineralcasting components that are bonded together. The fixingthreads in a grid arrangement and the integrated compressedair supply, with cast-in compressed air reservoir,result in a much more versatile component .Thanks to several built-in connections, a flexible utilisationof the compressed air is assured. A special lacquer coatingmakes the stand suitable for use in the medical industry.Basic housing for dental technologyIn the production of individual tooth crowns and multi-sectiondental bridges, blanks made out of special ceramicmaterials are used. To process these, 5-axis milling andgrinding machines are utilised, which are capable of implementingthe most complex geometries in a highly precisemanner. In addition, these machines are capable of achievingthe required high surface quality, especially in the areaof cracks and fissures at the edge of the tooth crowns.The illustrated structure is utilised as base for a machineof this type. The corrosion resistance, the outstandingdamping characteristics, the simple constructional featuresas well as the possibilities for a demanding designof the equipment are the essential advantages of mineralcasting RHENOCAST ® for this application.• 5FPD Inspection InstallationIn the production of flat panel displays for TVs and PCs, inspection installationscheck the integrated circuits of the screens. For this purpose, machine structureswith 3-axis displacement units are necessary.The illustrated machine structure, made out of vibration-damping mineral castingRHENOCAST ® , contributes to the fact, that the processing time can be considerablyreduced. The damping characteristics allow for a lower «step and settling time»of the drive. A special lacquer coating in addition renders the mineral casting structuresuitable for clean room applications. The components cast into the structureare manufactured out of stainless steel.Stand for wide-band grinding machinesSpecial wide-band grinding machines for grinding woodboards.The stand illustrated is part of a range of machines,which thanks to the characteristics of mineral castingachieves an optimum surface quality. The mineralcasting stand absorbs vibrations 10x better than conventionalsteel constructions. The complex structure isassembled and bonded together to form a stand out of4 or more simple mineral casting components and a steelgirder. This modular construction makes the most diversemachine types in 3 overall lengths possible.