Machine components made of UHPC

Solid machine beds and machine frames made of Ultra High Performance Concrete (UHPC) create the ideal basis to meet the demands of highly dynamic machines. High precision at increased feeding speeds is made possible on account of high damping. The innovative, high-performance material based on nanotechnology increases both rigidity and eigenfrequency and at the same time reduces sound emissions and minimizes wear and tear. Our state-of-the-art production facility guarantees the efficient and ecological manufacture of machine components using self-compacting, solvent-free, mineral high-tech concretes on the basis of a low temperature casting process with a good CO2 balance.

Material

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Technical data NANODUR-concrete

Characteristics Nanodur®-concrete E45 calculation data E45 Nanodur®-concrete E80 calculation data E80
Compressive strength
fcm
> 125 N/mm² σzul= 40 N/mm² > 150 N/mm² σzul= 40 N/mm²
Flexural tensile strength
fctm
15 N/mm² σzul= 5 N/mm² 20 N/mm² σzull= 5 N/mm²
Centric tensile strength - σzul= 3 N/mm² - σzul= 3 N/mm²
Static modulus of elasticity
Ec
46.500 N/mm² 45.000 N/mm² 84.500 N/mm² 80.000 N/mm²
Dynamic modulus of elasticity E 55.600 N/mm² - 89.600 N/mm² -
Poisson’s ratio μ 0,19 [ - ] 0,20 [ - ] - 0,20 [ - ]
Density of hardened concrete ρ 2.480 kg/m³ 2,5 to/m³ 2.790 kg/m³ 2,8 to/m³
Specific thermal capacity
cp
1,2 J/gK 1,2 J/gK 0,85 J/gK 0,85 J/gK
Thermal conductivity λ 3,0 W/mK 3,0 W/mK 6,0 W/mK 6,0 W/mK
Thermal conductivity
αT
12,0 · 10-6 [1/K] 12,0 · 10-6 [1/K] 7,0 · 10-6 [1/K] 7,0 · 10-6 [1/K]
Material Log.
damping decrement Λ
Damping ratio D [%]
Nanodur® concrete E45 0,030 0,50
Nanodur® concrete E80 0,021 0,33
Planning and Design

The company Sudholt-Wasemann GmbH supports the entire development process of a component from initial design to final product.
In this way, machine manufacturers can use and rely on our many years of practical experience in the material-specific design of machine frames made of UHPC. Together with our partners we can assist your engineering department to carry out feasibility studies, to design at optimal cost and to establish a 3D calculation on a FEM basis.

The development of a component made of UHPC allows for a number of various engineering measures in order to increase functionality. The integration of diverse built-in parts can be realized, e.g. steel rails, threaded sleeves, empty tubes, drains or pneumatic pipes. Even a prestressing of your elements up to a length of 15 metres is possible.

Mould Construction

Our specialists build individual, tailor-made moulds in our own mould construction department – from prototype to serial mould, everything from one source. Simple wooden moulds are often sufficient for individual moulds and prototypes. Depending on accuracy requirements and specific quantities of elements, precise serial moulds made of steel are used in addition to wooden or plastic moulds. As a result, mould-based accuracies of elements of 0.1mm are made possible.

Manufacture

A specialized team and modern mixing technique are responsible for the manufacture of our products made of UHPC. Our extensive know-how and experience and high motivation is needed to cast components with an individual weight of up to 20 metric tons. Made from aggregates, special bonding agent and water, the Ultra High Performance Concrete is cast into the prepared mould. UHPC is self-compacting and self-venting. These outstanding characteristics make mould construction easy and guarantee low wear and tear. By means of annealing it is possible to complete the setting process earlier, resulting in a reduced production time of the final cast component and its prompt further processing.

Further Treatment

In our own paint shop, components made of UHPC receive their final treatment
Two methods are possible:

Making a component water-repellent:
A simple process which only seals the UHPC without any visual effect.
Painting:
Realized through spray-coating with two-component lacquers.

Colour and scope of coating are individually adjusted to customer’s requirements.

Precision

Accuracies of 0.1mm can be achieved in a cost-efficient way on the basis of the suitable mould itself, i.e. without further treatment. They are guaranteed by internal quality management and our own measuring technology used for final inspection before the product is supplied to the customer. A straightness, evenness and parallelism of 0.005mm can be achieved by sanding the concrete surface. Cast-in steel rails represent yet another possibility. The rails are further processed in a high-precision machining centre. As a result of its thermal inertia, UHPC has a similar thermal expansion coefficient as steel. Thermal impacts on the components are low. Even at higher temperatures, UHPC is resistant to deformation.

Examples of Use

Delta-Tech Group machine bed
for special milling machine

Strama-MPS Machine test bench
The 3500 mm x 3500 mm bench weighs approx. 14 metric tons and is made of Nanodur® UHPC. Even if permanently exposed to hot media, it remains heat-resistant. The high-precision treatment of the built-in special steel parts represented a particular challenge.

FPT Robotik Robot cell

This robot cell is pured in one piece, the complete arrangement of wiring is done inside the mineral cast.

Working table

Depo lateral part

for portal milling machine

Planolith precision measuring bar
and measuring angle made of »Novalith« (special recipe)

HOMAG Group moving-column machine

for the woodworking industry

PTW Technologies GmbH machine bed

for processing machines

HOMAG Group machine bed

for sanding machines

Johann Fischer machine bed

made of »InnoCrete« (special recipe)

HOMAG Group drill rig
with linear guide rails directly bolted on concrete. Due to a special moulding construction and production process, an evenness accuracy of 0.1 mm over a length of 2,00 mm is achieved.

Polytec stand

for measuring machine

HOMAG Group portal

Polytec portal

for measuring machine