Processing Guidelines BWF e
Processing Guidelines BWF e
Processing Guidelines BWF e
products made by
BWF Kunststoffe GmbH & Co KG
Date 08.02.2018
Scope of application
These quality and tolerance specifications as well as processing guidelines are valid for all
products manufactured or supplied by BWF Kunststoffe GmbH & Co KG.
Table of contents
1. Tolerance Specifications Extrusion ..................................................................................................... 4
1.1. General tolerances........................................................................................................................... 4
1.1.1. Cross-section ............................................................................................................................... 4
1.1.2. Longitudinal direction ................................................................................................................... 5
1.2. Tolerances of shape and position .................................................................................................... 6
2. Approval process................................................................................................................................... 8
2.1. Adjustment drawing ......................................................................................................................... 8
2.2. Sample ............................................................................................................................................. 8
2.3. FAI report ......................................................................................................................................... 8
2.4. Functional check .............................................................................................................................. 8
2.5. Production drawing .......................................................................................................................... 8
3. Quality insepections .............................................................................................................................. 9
3.1. General Information ......................................................................................................................... 9
3.2. Functional check ............................................................................................................................ 10
3.3. Dimensional inspection .................................................................................................................. 10
3.3.1. Length testing ............................................................................................................................. 10
3.3.2. Straightness ............................................................................................................................... 10
3.4. Surface ........................................................................................................................................... 10
3.5. Classification of surface imperfections ...........................................................................................11
3.6. Color ............................................................................................................................................... 12
3.7. Saw cut .......................................................................................................................................... 13
3.8. Stress test ...................................................................................................................................... 14
4. Handling Guidelines ............................................................................................................................ 15
4.1. Storage ........................................................................................................................................... 15
4.2. Moisture absorption ....................................................................................................................... 15
4.3. Thermal change in length .............................................................................................................. 15
4.4. Protection ....................................................................................................................................... 15
4.5. Cleaning ......................................................................................................................................... 15
4.6. External influences in installation................................................................................................... 15
5. Processing Guidelines ........................................................................................................................ 16
5.1. Tensions in plastic parts ................................................................................................................. 16
5.2. Machining ....................................................................................................................................... 16
5.3. Machining and sheet saw tolerances ............................................................................................ 16
5.4. Drilling ............................................................................................................................................ 17
5.5. Milling ............................................................................................................................................. 17
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5.6. Laser cutting................................................................................................................................... 17
5.7. Punching ........................................................................................................................................ 17
5.8. Polishing......................................................................................................................................... 17
5.9. Threads .......................................................................................................................................... 18
5.10. Screw connections ........................................................................................................................ 18
5.11. Clamping ....................................................................................................................................... 19
5.12. Gluing ............................................................................................................................................ 19
5.13. Welding ......................................................................................................................................... 19
5.14. Rivets ............................................................................................................................................ 20
5.15. Tempering ..................................................................................................................................... 20
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1. Tolerance Specifications Extrusion
1.1. General tolerances
In the case of general tolerances, a distinction is generally made between two types of observation:
On the one hand, the profile cross-section is viewed and, on the other hand, the longitudinal direction of the profile. The general
tolerances apply if nothing else is indicated on the profile drawing.
The following limit values apply according to DIN 16941 - 2A and 2B, unless otherwise stated in the drawing
1.1.1. Cross-section
The general tolerances apply at any point in the profile.
The profile cross-section to be viewed is at right angles to the extrusion direction:
profile cross-section
(90 ° to the extrusion direction)
2A and 2B ± 0,3 ± 0,4 ± 0,5 ± 0,6 ± 0,7 ± 0,8 ± 1,0 ± 1,2 ± 2,0 ± 3,0
4
Allowed limiting dimensions for rounding and chamfer heights:
Reference width
fp
Profillängsrichtung
Profile longitudinal
(direction (extrusion
Extrusionsrichtung)
direction)
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1.2. Tolerances of shape and position
Straightness:
Straightness in X-direction: straightness tolerance tg (for example tg = ± 1.5 mm on a length of 1000 mm)
Straightness deviation fg
length
References
l=1000mm
Figure 4: Straightness in the X direction
Straightness in the Y direction: straightness tolerance tg (for example tg = ± 1.5 mm on a length of 1000 mm)
Straightness deviation fg
fg
Reference length
l=1000mm
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Distortion: Straigntness tolerance tv, straoghtness deviation fv
twist tolerance tv in degrees:
fv
diameter du
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2. Approval process
2.2. Sample
After completion of the tool, the first test production ("adjustment") begins. Based on the results of this adjustment, the tool may
pass through several stages of rework until the extruded profile cross-section is both dimensionally and functionally (see point
2.4) accurate. Following the final adjustment, samples are produced, which must be checked and approved by the customer
prior to the profile entering production stage. The samples may either be approved solely by the customer, or together with the
customer, in the case of a profile inspection at BWF Profiles. The approved samples are archived by BWF Profiles and serve as
a reference for comparative tests for all subsequent serial productions.
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3. Quality insepections
All tests listed below are carried out every 2 hours during production and documented in the relevant quality records.
Test pieces
During every production, 100mm test piece, clearly marked with date, time, arrow for extrusion direction as well as a red line for
inline cutting are to be taken.
In the case of multiple extrusion, a test piece is to be prepared from each strand and marked as described above.
Figure 7: 10 cm pattern with correct inscription and marking of the inline cut
At the start of production (SP) and end of production (EP), a 1,000 mm test piece, marked with profile number, date and time, is
additionally checked and archived.
Comparative tests must always be carried out between test piece and approved sample, as well as between test piece and PS
samples.
The following tests shall be carried out and confirmed on the quality record:
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3.2. Functional check
If test gauges are available, a functional test must be carried out.
The test is carried out in the application situation using 100mm samples.
Twice per shift, a functional test with a longer profile is carried out in the customer installation jig.
In the case of symmetrical profiles, an overlap check is carried out at SP, as well as once per shift and after corrections.
The dimensional test for tubes is carried out via a measuring machine.
The straightness of profiles is tested in X and Y direction. For round tubes, the max. deflection is checked. The specifications
are listed on the BWF Profiles drawing.
Precise lenghts:
Precise lengths are measured and documented on the measuring table, taking into account the change in length due to
temperature and humidity, as stated above. The indicated lengths refer to the reference temperature of 20 ° C. At the start of
production and as well as at any change in length, at least 5 pieces of the current application length are checked at the
measuring table.
Multiple lengths:
Multiple lengths are measured and documented using a tape measure.
3.3.2. Straightness
The straightness is checked according to the specification at the straightness measuring table.
For profiles the test must be carried out in X and Y direction.
For round tubes, the maximum deflection must be measured.
3.4. Surface
Profiles:
From a distance of approx. 1 m, a purely optical inspection takes place in the visible region of the entire component, both in the
illuminated and in the unlit state. The test duration is 10 seconds per meter. No obvious inclusions, scratches caused by
mechanical damage, or extrusion lines, unless caused by the natural extrusion process, are allowed.
Sheets:
Sheets made of PMMA base material are manufactured according to EN ISO 7823-2.
Sheets made of PC base material are manufactured according to the surface requirements according to EN ISO 7823-2 4.2.
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3.5. Classification of surface imperfections
Based on the prevailing sheet specifications for extruded plastic sheets - DIN ISO 7823-2 for PMMA materials and 11963-2013-
0P3 for PC materials - the specifications for extruded sheets made by BWF Profiles have been amended more strictly and can
be interpreted as described in the available document.
We check the surface quality in accordance with the template. The below mentioned test criteria apply.
As a reference plane, an area of 0.36m² applies which is for example 600mm x 600mm
Different shapes
of inclusions
Please print the available template on transparent foil for rating the material inclusions in sheets supplied
by BWF Profiles.
Scale in mm
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3.6. Color
Individual coloring is possible. The customer receives color samples ("color strips") in advance. The color of the first samples of
BWF Profiles is assessed and released on the basis of the color strip approved by the customer.
BWF Profiles carries out a visual comparison test (top-view and transmission) in the illuminated and unlit state in comparison to
the approved sample.
The illuminated test is carried out in the installation situation of the customer or (if not available) with the customer's illuminant at
the respective workplace on the machine. The allowed color deviation isΔE≤3.
In the case of non-colored profiles, a visual comparison test of the inherent color must be also carried out.
Figure 8: Top view test in incident light; Work lamp (transmission) is switched off
Transmission test:
Visual inspection in the lit condition.
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3.7. Saw cut
A distinction is also made between precise lengths and multiple lengths in the case of the saw angle. For precise lengths, the
saw cut quality as well as the saw angle are assessed. The saw angle is measured at the angle stop.
Gap size:
Gap S maximum for HEIGHT
Offline cut
S
L
A table with the permissible tolerances for the clearance can be made available if required. The quality of the saw cut is
assessed by visual inspection:
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Measurement possible with the measuring table => length and angle test [mm] Measuring tape,
no angle test
< 500 > 500 > 1000 > 1500 > 2000 > 3000 > 4000 > 4500
± 0,3 ± 0,5 ± 1,0 ± 1,5 ± 2,0 ± 3,0 ± 4,0 ± 0,1%
Inline cut
Measurement possible with the measuring table => length and angle test [mm] Measuring tape,
no angle test
< 500 > 500 > 1000 > 1500 > 2000 > 3000 > 4000 > 4500
± 0,5 ± 0,8 ± 1,0 ± 1,5 ± 2,0 ± 3,0 ± 4,0 ± 0,1%
1) In the case of multiple lengths, in which there may be tears on the profile ends, the tolerance +20 mm is maintained and cut
to length with the crosscut saw.
2) An inline saw is required for multiple lengths with a required clean cut. Profile cuts are maintained with a tolerance of +10
mm.
3) Inline cuts for fixed lengths can be manufactured with the above tolerances.
Note: Measuring lengths over 4500 mm can no longer be checked with the length measuring table, so no angle test is
possible and the profile blanks must be measured with the measuring tape
± 0.1% tolerance.
Profiles:
No standard stress test is required for profiles.
Tubes:
For tubes. The following standard stress test shall be carried out at the start of production, once per shift and when changing
production parameters:
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4. Handling Guidelines
4.1. Storage
It is not recommended to store plastic products in the open, as weather-related influences may impair or damage the material. It
is recommended to store plastic products on a flat base at an ambient temperature of 20 ° C and an average humidity of approx.
50%.
4.4. Protection
To avoid contamination and scratches, BWF Profiles puts a protective film on the profile surface (visible side). This film must be
removed no later than six months after delivery. The plastic parts must be protected from direct sunlight, since changes in the
adhesive film due to temperatures above 40 ° C and UV radiation may occur. As a result, glue residues can form on the surface
of the plastic parts. The protective film must also be removed prior to a possible vacuum forming process. When the protective
film is peeled off, a static charge can occur, which attracts dust and dirt particles. Possibly an antistatic treatment is necessary
(e. g. with ionized compressed air) before further processing.
4.5. Cleaning
Water is sufficient to clean PMMA and PC. In the case of heavier soiling, the water should be slightly heated and treated with a
mild detergent (e.g., soap). Rubbing on dry material should be avoided. Before drying the material (e. g., using a sponge),
ensure that any particles on the surface have been removed to avoid scratches.
In the lighting industry, plastic parts are installed together with electronic components such as ballasts, cables, etc. As a result
of rising operating temperatures in the luminaire, these components increase the risk of emission of volatile constituents. If
these volatile constituents are aggressive or corrosive, the tensile strength of the plastic parts is reduced, which can lead to
stress cracking. Therefore, electronic components must be specifically suitable for use with amorphous plastics such as PMMA
or PC. If the properties of the electronic components are unclear, their influence on the plastics must be tested before
installation in order to avoid possible damage.
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5. Processing Guidelines
A reduction of the internal mechanical stresses caused by additional machining is achieved by subsequent annealing (see point
5.15.). If the stresses are not reduced as recommended, subsequent processing steps can cause damage to the material (e. g.,
cracks, breaks, etc.), e.g.
• bonding
• painting
• tempering (under false conditions, e.g. temperature, duration)
• cleaning
5.2. Machining
Plastic profiles made of PC or PMMA can usually be machined with most of the tools which are also used in the processing of
wood or metal. The tool speeds must be chosen in such a way that the material does not melt due to frictional heat.
Cutting tools must always be kept sharp. Since plastic has poor thermal conductivity, the heat generated by machining must be
absorbed by the tool. Ensure that the tool is cooled (e. g. by directed airflow). Cooling lubricants must be tested for chemical
resistance in contact with plastics prior to use.
to 50 above 50 above 120 above 250 above 400 above 1000 above 2000 above 4000
to 120 to 250 to 400 to 1000 to 2000 to 4000
Width / Length: Tolerance package cut Tolerance single cut Tolerance CNC
10 bis 49mm +/- 0,3mm +/- 0,3mm +/- 0,3mm
50 bis 200mm +/- 0,4mm +/- 0,3mm +/- 0,3mm
201 bis 500mm +/- 0,5mm +/- 0,4mm +/- 0,3mm
501 bis 750mm +/- 0,6mm +/- 0,5mm +/- 0,3mm
751 bis 1000mm +/- 0,8mm +/- 0,6mm +/- 0,4mm
1001 bis 2000mm +/- 1,2mm +/- 1,0mm +/- 0,8mm
2001 bis 3050mm +/- 2,0mm +/- 1,5mm +/- 1,2mm
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5.4. Drilling
Blunt drills which are unsuitable for plastic processing must be avoided. Standard spiral drills for wood or metal can be used.
However, it is recommended to use special drills designed for plastics.
Care must be taken to avoid overheating due to friction. Chips must be removed continuously. The drill part must be secured or
clamped in order to avoid cracking or slipping.
5.5. Milling
For milling, universal, copying, table and manual milling machines are used. The cutting speeds must be adapted to the
respective plastic. For small tool diameters single or two-edged finger milling cutters should be used.
They allow for a high cutting speed due to their good chip removal and create nice edge images. For single-edged cutters, the
chuck must be carefully balanced to avoid marking on the component.
5.7. Punching
It is possible to punch PC profiles and sheets up to a thickness of 2mm when
regular, very sharp tools suitable for metal working are used. In this case, the sheet must always rest firmly against the counter-
edge / blade in order to avoid squeezing. The punching of PMMA profiles and sheets is not recommended.
5.8. Polishing
Products from BWF Profiles can be polished on the saw or milling edges to remove machining marks. There are two
possibilities: dry or wet grinding and polishing with a diamond milling machine. It is important in any case to ensure that the
plastic surfaces do not come into contact with abrasive paper. This leads to permanent surface damage which cannot be
removed.
When polishing by hand, the polishing process must be preceded by a grinding operation. Grinding paper of 80-600 grit is
recommended for grinding by hand. In this case, it is necessary to work from coarse to fine in several grinding operations. For
machine grinding, belt grinding machines with a belt speed of 5-10 m / s should be used. High temperatures of the material
surface are avoided by only slightly pressing the work piece under movement.
Another possibility is polishing with diamond tools. A good surface quality can be achieved within a few runs without pre-
grinding. No further processing is needed. With this technique, there are hardly any internal stresses. Tempering, necessary for
the other methods can be omitted if necessary.
Flame polishing is only recommended for PMMA since the polishing edges of PC turn brown due to the high heat development
and there is a build-up of high stress in the processing area, which can adversely affect the mechanical properties.
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5.9. Threads
The cutting of internal and external threads with PMMA and PC plastic parts is not recommended as this causes internal
stresses. Instead, thread inserts made of plastic (not soft PVC) should be used (see illustration). Please note: D> d to prevent
tensions.
The clamping forces acting on the plastic part decrease with falling temperatures and increase with rising temperatures. This
effect can be compensated by the use of washers made of EPDM, PE, PTFE (non-plasticized PVC!), etc. (see figure below).
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Example of suitable screw connections:
EPDM washer (1), plastic part (2), counterpart (3), protective film (eg PE) (4), screw with large washer and screw head (5),
welded bolt (6), flat metal part (7), Cap nut (8), EPDM strip (9)
Self-tapping screws, which penetrate only into the plastic, are not suitable. However, they can be used if the thread is in contact
with a metal counterpart and through holes are provided in the plastic (see above). In addition, the head of the self-tapping
screw as well as the washer must be large enough as described above.
5.11. Clamping
If amorphous plastics, such as PMMA or PC, are installed by clamping forces, the effective forces must be distributed over the
largest possible area and sufficient space for the material expansion must be provided. To avoid stress cracking, elastic seals
(see section 4.6) must be selected. The clamping pressure must be kept as low as possible, as this may cause friction between
the plastic and the seal. This friction prevents the plastic part from slipping when expanded by heat or moisture.
5.12. Gluing
In order to reduce internal stresses caused by extrusion, injection molding, sawing, milling, drilling, tapping, thermoforming,
welding, etc., the plastic part should be annealed before gluing (see Tempering). Most liquid adhesives and adhesive solutions
also increase the risk of stress cracking.
Stress cracks can be caused by internal as well as external stresses. External stresses are generated by large clamping forces
during the positioning of the various plastic parts to be bonded. These are to be avoided.
5.13. Welding
Amorphous plastics such as PMMA or PC can easily be welded. Upon heating, these materials undergo a short viscoelastic
range (rubbery elasticity) before becoming soft and moldable over a wide temperature range. The connection in the welding
area can be achieved in various ways, e.g. welding with heating mirror / heating element, beam welding, ultrasonic welding, etc.
These welding techniques generate a high degree of tension in the welding area. This stress is caused by the much higher
temperatures in the welding zone compared to the cooler outer areas.
The clamping forces necessary for positioning the welded parts can also lead to an excessive tension in the plastic part.
Therefore, the clamping forces should be adjustable in order to avoid cracks in the plastic part.
If the influence of corrosion agents is to be expected during subsequent installation, tempering is recommended.
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5.14. Rivets
The use of rivet connections with PMMA or PC using metal rivets is not recommended.
For these materials, expanding rivets or clip rivets made of plastic are recommended. These are commonly available (see
below).
Expanding rivet: (1) plastic, (2) metal Clip rivet: (1) plastic, (2) metal
5.15. Tempering
During tempering, plastic parts are first heated and then slowly cooled again.
Plastics can withstand the permissible stresses as long as they are not exposed to corrosion agents at the same time. Decisive
for successful heat treatment is the adherence to a material-dependent temperature program.
Tensions can be caused, among others by:
Contact with corrosive agents, such as solvents and diluents during gluing, printing or varnishing, gassing during laser cutting or
flame polishing, softeners in PVC insulations, seals and protective films, as well as aggressive detergents, can lead to hair
cracks that make the parts unusable.
The simultaneous occurrence of tensions and corrosive media should be avoided.
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Since it is impossible to completely avoid tensions (see examples above), these must be eliminated by stress-relieving
annealing.
PMMA and PC have to be tempered in a suitable furnace. During a sufficient tempering time, the temperature must be below
the softening point. Subsequently, the plastic part is slowly cooled. When cooling is too rapid, a cold, stiff outer layer is created,
which in turn can create stresses, since the hotter material inside shrinks more than on the outside (see below).
Parameter PMMA:
From ambient temperature to 80 ° C within 1h
3h + t [h] (wall thickness 1-3 mm)
Cool to room temperature not faster than 15 ° C / h
(E.g. If the wall thickness is 1mm, then hold 3h + 1h = 4h
Parameter PC:
von Umgebungstemperatur auf 120° innerhalb 1h aufheizen
3h + t [h] (Wandstärke 1-3 mm) halten
Abkühlen auf Raumtemperatur nicht schneller als 15°C/h
z.B. wenn die Wandstärke 1mm beträgt, dann 3h + 1h = 4h halten
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BWF Kunststoffe GmbH & Co. KG
Bahnhofstraße 20
89362 Offingen
Germany
Phone +49 8224 71-601
Fax +49 8224 71-2145
[email protected]
www.bwf-profiles.com