News
Producing door panels in a
batch size of 1
The new machine is a unilateral IMA Combina through-feed system, which is equipped with a double feed chain due to the heavy workpieces that can be processed.
Perfect quality from Neuform: Door panel with foiled edges without chipping; double rebate and 3.5mm door seal
Schallex grooves without chipping
These tool sets trim blunt end door panels and cut the Schallex-grooves in different widths.
The flashover is fine trimmed. There are no visible cutter marks even after lacquering.
The prism rebate cutter works at an inclination of 45° and enables smooth rebate surfaces without any visible cutter marks.
The scoring hogger inwardly removes various top surfaces and core materials in a step cut design, which prevents chipping of the trailing edge during cross-processing.
Small production batch, high quality expectations -
LEUCO a competent partner for door manufacturers
The Neuform-Türenwerk (door manufacturer) has set new standards with its latest major investment. Not only the variety of doors manufactured, but also the flexibility as well as the productivity of this new machine is vast.
Neuform –Türenwerk Hans Glock GmbH & Co. KG manufactures door panels at 2 locations with approximately 240 employees in Germany.
Door sizes of up to 3200 x 1600 mm, with a thickness of up to 90 mm and therefore a mass of up to 250 kg per panel, illustrate the extremity of the necessary specifications of the machine and tooling.
The new machine is a unilateral IMA Combina through-feed system, which is equipped with a double feed chain due to the heavy workpieces that can be processed.
Whether 4 or 10 passes are needed per door until finished, the selection of LEUCO tools meets the necessary requirements.
In order for each door panel to be finished, it has to pass through the machine several times. A simple rebate model has to pass through the machine 4 times, a more complicated design may need to pass through up to 10 times before being finished.
Some of the tooling configurations for this machine will now be presented. At stations 1 and 2, the panel is scored with the feed. This is carried out by a scoring hogger, which inwardly removes various top surfaces and core materials in a step cut design, which prevents chipping of the trailing edge during cross-processing.
Station 3 is a servo-controlled scoring unit, and at station 4 the whole cutting width is milled with a hogging tool. It is important to cut with a minimised feed rate per tooth; this is also the case for the second and third hogging lines. At stations 5 and 6 the rebate is milled in alternate directions, the second aggregate is a jumping spindle.
At stations 7, 8, 9, 37, 38 and 39 the whole range of door panels are trimmed and Schallex-grooved in alternate directions with an automatic controlled z-axis. The Neuform product range covers 8 – 34mm and all common double-grooves for the complete door panel.
The jointing cutters are all specifically designed for each door panel width to achieve maximum cutting quality and tool life. For example, the cutters for processing fire-doors have special tooth geometry and cutting material. It is remarkable, that in between these corresponding aggregates there are 26 further stations. The reason for this is the limited space in the formatting section, at the same time this proves the precision of machine and tooling when the same Schallex-groove is processed over such a distance without any offset.
There is yet another LEUCO specialty at station 10. The rebate is processed with a special prism rebate cutter at an inclination of 45°. In this way a long and soft tooth entrance can be achieved. This helps to smoothen the surface and to make the usual cutter marks almost invisible – even after lacquering or spraying.
Now the conventional part of door panel and rebate processing is commenced. One specific aggregate is the double-ripping unit; here the overhang is scored in 2 lines to enable the precise positioning of the veneer in the rebate.
At stations 34 and 35 there is a rebate clipping saw with a lower positioned raker tip to avoid adhesion on the side of the teeth. On the multi-profiling units, different radii and bevels can be processed in a batch size 1 manner, within a gap of less than 400mm. All these rebate processing aggregates have in common that they are specifically designed to cover the extreme variety of door panels and ensure the highest possible productivity of the line.
In a project like this, the challenge for the tool manufacturer is to define together with the customer and the machine manufacturer the technical parameter, performance requirements and processing line-up as well as to support the customer during installation and set-up of the line. LEUCO proves once more to be an innovative, trend-setting and reliable partner for the door manufacturing industry.
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