SeiatSu air-Flow Squeeze Moulding ProceSS - Heinrich Wagner Sinto

SeiatsuAir-Flow SqueezeMoulding Processwww.sinto.com

SEIATSU... the process for producing consistently perfect moulds.The process sequence.The SEIATSU air flow squeeze moulding process is amethod of compacting moulding sand. The required quantityof sand is released when the louvre shutters of the sand dosinghopper are opened. The mould is formed by a patternplate mounted on a pattern bolster. A guiding frame on topof the moulding box guides the sand into the box (fig. 1).The sand dosing hopper underneath the sand storage hopperthen moves to the side and simultaneously the squeezehead moves in position over the mould. The machine tablerises thus pressing the bottom bolster (including the mouldingbox and filling frame) against the squeeze head, hermeticallysealing the system. The SEIATSU air flow valve isthen opened. The air is passed through the moulding sandfrom the back of the mould and towards the pattern. Ventsprovided on the pattern plate or on the pattern itself facilitatethe air flow simultaneously through all the components(fig 2).The mould is then compacted by applying pressure in anarrangement that may use a squeeze plate, an elasticsqueeze plate or a multi-ram press (fig. 3). Whilst the compactingprocess is proceeding the dosing hopper is refilled.To separate the mould and the pattern the machine tableis lowered and the sand dosing hopper and the squeezinghead are moved back to their datum position (fig. 4).• The sand is filled into the mould box to cover the pattern• The SEIATSU AIRFLOW Squeeze Moulding Process is applied• Mould example: Brake drum, Ø approx.: 500 mm• Mould example: Cylinder heads, flasksize: 1550 x 1100 mm2

The advantages of the SEIATSU process.Measuring pointsSand height (in mm)20018016014012010080604020JoltingJolting + squeezingAirflowAirflow + squeezing = SEIATSUCoreJolt Squeeze Machinewith coreSEIATSUSqueeze Moulding Processwithout coreSelfcore ingreen sand285Taper 0,5°32000 10 20 30 40 50 60 70 80 90 100Mould hardness (GF units)ø170ø200Uniformly high mould hardness.The moulds produced are uniformly hard resulting in theproduction of dimensionally accurate castings. The mouldsproduced by the SEIATSU air flow process are considerablyharder than those produced by jolt squeezing.Fewer cores required.In many cases cores can be eliminated when mouldingcomplicated pattern shapes and extreme cods with theSEIATSU processø 260100air flow-squeezing25021200803Amould hardness604020jolt-squeezingDistance A 20Measuring pointsMean value123787885803082818583408483858450858486856085858886Jolt-squeezing0 10 20 30 40 50 60 70Mean value–50626872distance A in mmReduced pattern draft.Draft can be reduced to 0.5° when using the SEIATSUprocess, resulting in corresponding reductions in use ofmaterial and in machining costs.Improved utilisation of the mould space.The ability to reduce the distance between patterns fromeach other and the side of the mould results in improvedutilisation of the available space and hence more castingsper mould.D2D1D2D1H2H1H2H1mmMaximum variation rangekg mm–1,2–0,8 –0,4 0 0,4 0,8 1,2Maximaler StreubereichD1 kg –1,2 –0,8 –0,4 0 0,4 0,8 1D2H1H2CastingweightD1D2H1Air H2 flow squeeze mouldingJolt Gussteilgewichtsqueeze moulding4Luftstrom-Press-FormverfahrenRüttel-Press-Formverfahren

Gas penetration resistance Gd10090807060without air currentwith air currentReduction in fettling costs.The SEIATSU process achieves consistently high generaland surface quality, and dimensional accuracy with almostno burrs, so that fettling requirements and machining costsare very considerably reduced.5015 20 25 30Compression resistance N/cm 3–3 –2 –1 0 1 2 3L = 810 mmB = 397 mmH = 152 mmWeight of casting162 kgSEIATSU-PROCESSCasting tolerances/GTB15, DIN 16851. Using pressure aloneporosity 29,2 %2. Using air flow and pressureporosity 32,9 %Comparison of the noise emissionComparison between jolting of the and noise SEIATSU emissionbetween jolting and SEIATSUlevel time signal of alevel jolt moulding time signal machineof ajolt moulding (ram jolter) machineComparison (ram of the jolter) noise emissionbetween jolting and SEIATSU110 dB(A)level time signal of ajolt moulding machine(ram jolter)110 dB(A)100 dB(A)100 dB(A)90 dB(A)90 dB(A)85 dB(A)85 dB(A)80 dB(A)80 dB(A)110 dB(A)100 dB(A)90 dB(A)85 dB(A)80 dB(A)Vibration speed in mm/sDynamic load in the surroundings of moulding machines201086543210,80,60,50,40,30,2admissible rangeSEIATSU moulding machinejolt-squeeze moulding machinelevel time signal of alevel level time signal of of aair flow aair flow squeeze moulding moulding machine machineair flow squeeze moulding valve) machine(open valve)(open valve)Environmental advantages.Where the jolt squeeze process is replaced by the air flowsystem noise levels are brought down to 85 dB(A). Thisbrings a major improvement in the working conditions in a0,1302 3 4 5 6 8 10 20 30 40Distance of the machine in mfoundry. The SEIATSU process does not produce shockloads so that the foundation requirements are simplified,the impact on the surroundings is reduced and there is lessneed for maintenance.5

EFA-SFully automatic lowering moulding machinewith pattern roller conveyor and patternshuttle truck for the production of cope anddrag moulds, equipped with multi-ram pressas standard equipment. Sand filling by batchhopper. Moulding box handling by means ofhydraulic cylinder on roller conveyors.Moulding boxInside sizes mm1000 x 8002500 x 2000Output approx.compl. m/h6020EFA-SDFully automatic lowering moulding machinewith pattern turntable for the production ofcope and drag moulds, equipped with multirampress as standard equipment. Sand fillingby batch hopper. Moulding box handlingby means of hydraulic cylinderon roller conveyors.ZFA-SFully automatic twin-type moulding machinefor simultaneous production of one cope andone drag mould, with pattern roller conveyorand pattern shuttle truck, equipped withflat squeeze plates, elastic squeeze platesor multi-ram presses. Sand filling by batchhoppers. Moulding box handling by meansof hydraulic cylinder on roller conveyors.Moulding boxInside sizes mm500 x 4001600 x 1250Moulding boxInside sizes mm500 x 4001250 x 1000Output approx.compl. m/h14080Output approx.compl. m/h250160ZFA-SDFully automatic twin-type moulding machinewith pattern turntable for the production oftwo cope or two drag moulds or one mouldingbox pair, equipped with flat squeezeplates, elastic squeeze plates or multi-rampresses. Sand filling by batch hoppers.Moulding box handling by means of hydrauliccylinder on roller conveyors.Moulding boxInside sizes mm500 x 4001250 x 1000Output approx.compl. m/h2501607

SEIATSU examples of aluminium casting• Gearboxmaterial: EN-AC, mass: 24 kg• Oilpanmaterial: EN-AC, mass: 33 kg• Cagematerial: EN-AC, mass: 4 kg• Oilpanmaterial: EN-AC,mass: 31 kg• Valve cagematerial: EN-AC, mass: 0,5 kg9

SEIATSU a perfect casting• Hitch cagematerial: EN-AC, mass: 12 kg• Exhaust cagematerial: EN-AC, mass: 4 kgHEINRICH WAGNER SINTOMaschinenfabrik GmbH SINTOKOGIO GROUPBahnhofstraße 101 ·• D-57334 Bad Bad Laasphe, Laasphe GermanyPhone Tel +49 +49 (0) (0) 2752 2752 907-0 907-0 • Fax · Fax +49 +49 (0) (0) 2752 2752 907-280 907-280www.wagner-sinto.deDIN EN ISO 9001:2000Zertifikat: 09 100 72018VO · 1000 · 06/1107-280