What is mineral casting?
Mineral casting is a proven innovative construction material with versatile properties and excellent vibration damping. It consists of hard rocks with varying grain sizes that are combined with binding agents (e.g. epoxy resin) and special additives to produce a casting compound specially tailored to the individual requirements. Thanks to mineral casting technology perfected by leading tool manufacturers, components today can be cast to an accuracy of a few tenths of a millimetre with respect to dimensions, shape and position. In air-conditioned moulding halls, linear guide systems can even be cast to an accuracy of a few thousandths of a millimetre.
Pioneers of panel-sizing technology
The challenge: never before had this material been used in horizontal panel-sizing technology. "We acted as pioneers in this area and conducted valuable development work," says Eckard Hörner-Marass, Managing Director of HOLZMA Plattenaufteiltechnik GmbH, and goes on to explain: "Even during the draft phase, we calculated the geometry of the saw base using the FEM* method. This allowed us to determine the best structural rigidity, vibration damping and material usage. The team under Dr Geert Schellenberg from the Materials Testing Institute then defined and carried out various endurance tests in consultation with our engineers."
Weeks of intensive tests
The effects of cyclical stresses caused by acceleration and braking processes in the saw carriage station were checked as well as the effect of the many million load changes from the pressure beam on the saw body during the saw's service life. The effects of non-braked collisions with the buffer, for example in the event of a malfunction, on the stability of the mineral casting base were also examined. The Materials Testing Institute tested the saw body millions of times in various test runs at loads much higher than the rated load and under extreme conditions.
The result is a saw body for the 5 series that has successfully passed all load and durability tests from the Materials Testing Institute. This proven material has now for the first time found its way into horizontal panel-sizing technology and is opening up new avenues in cutting dynamics, vibration compensation and cutting speed. HOLZMA customers can benefit from this here and now.
*FEM = Finite Element Method