CPT International 01/2016

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Production hall of Grunewald GmbH in Bocholt, Germany. For the last several years the company has particularly developed the low-pressure casting of thin-walled aluminum sand castings (Photo: Andreas Bednareck) Authors: Anton Gieniec, Business Line Manager No-Bake Europe, Natascha Hurkes, Head of Laboratory, Peter Vietoris, Area Sales Manager Germany North West, ASK Chemicals, Hilden, and Harald Dieckhues, Foundry Manager, Grunewald GmbH, Bottrop mentally friendly binder system The demands of global competition are growing all the time. Besides high cost pressure and short delivery times, foundries need to meet the highest quality requirements. In time for its 50th anniversary, Grunewald, Bocholt, Germany, has taken account of these needs. With a new hall and ultramodern process technology in the molding shop and reclamation plant, it has been able to increase its capacities considerably. Meanwhile an inno vative Pep Set system, which is optimally tuned to local processes, has been developed together with ASK Chemicals from Hilden, Germany Next to tool and component construction, the casting segment is the third largest pillar of the international firm of Grunewald company, which employs 240 staff at six sites worldwide. Grunewald is one of Europe‘s leading manufacturers of thin-walled aluminum structural parts for the automobile sector, the semiconductor industry and machinery construction, possessing excellent know-how in prototype and small series production for the different industries. Owing to new and increasingly varied customer demands and rising cost pressure, the foundry was expanded to a total 2800 m 2 in 2013. This was an important step toward safeguarding the future and enabled the company to concentrate and restructure the whole production at one site. Already in the early stages, work was carried out in conjunction with ASK Chemicals on changing the binder 8 Casting Plant & Technology 1/2016
system in order to achieve further optimization in terms of processing and costs, such as improvement in the casting quality and greater productivity in mold making. The furan resin system used hitherto was, first of all, unable to satisfy the demands for an improved casting surface with simultaneously improved productivity. Likewise, the reclamation of used furan sand is subject to certain limitations: a thermally reclaimed mold material produced by an acid-hardening process has a high proportion of metal oxides. These metal oxides slow down the acid-catalyzed hardening reactions on the reclaimed material (Figure 1). The use of a thermally reclaimed mold material compared to fresh sand and mechanically reclaimed sand prolongs the strip time almost threefold. To bring reactivity (the strip time) to the level of mechanically reclaimed sand, it is necessary to increase the acid catalyst amount by approx. 30 %. An increase of the acid catalyst, however, leads to a considerable increase in SO 2 emissions and also comes along with a deterioration of the casting quality. Thermal sand reclamation was not planned initially, but after extensive analysis it offered the advantage of a higher quality of reclaimed material and, due to the increased proportion of reclaimed sand, an almost 15 % reduction in the waste sand requiring disposal. Due to its many outstanding advantages, the polyurethane no bake system, so-called Pep Set system, was a potential alternative system for Grunewald. Pep Set binders are based on a polyaddition reaction between a phenolic resin (polyol component) and an isocyanate component. Pep Set involves a 3-component system consisting of a binder (Part 1), a hardener (Part 2) and a liquid catalyst. Hardening occurs without the formation of elimination and by-products such as water or formaldehyde (Figure 2). The Pep Set system is characterized by a relatively long processing time with simultaneously very rapid curing (Figure 3) and thus guarantees maximum productivity thanks to very fast cycle times. Figure 1: Reactivity of a furan resin system with fresh sand, mechanically reclaim ed and thermally reclaimed sand (Photos and graphics: ASK Chemicals) Figure 2: Curing reaction of a Pep Set system Figure 3: Hardening diagram of a Pep Set system compared to a furan resin system Casting Plant & Technology 1/2016 9
Page 1 and 2: www.giesserei-verlag.de March 2016
Page 3 and 4: EDITORIAL The Chinese dragon takes
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Page 14 and 15: Modernized melting shop at a foundr
Page 16 and 17: ECO-FRIENDLY PRODUCTION Author: Flo
Page 18 and 19: ECO-FRIENDLY PRODUCTION -85 % -97 %
Page 20 and 21: The combination of cleaning agent a
Page 22: QUALITY ASSURANCE Figure 3: Feeding
Page 25 and 26: Metal Fabrication at Tyrolit. “Es
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Page 38 and 39: COMPANY An aerial view of the Heger
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Page 42 and 43: SPECIAL Author: Wen Ping, Executive
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NEWS VOXELJET Topology optimization
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NEWS RECYCLING tonnes of CO 2 are
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NEWS ASK CHEMICALS Exactcast techno
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BROCHURES Molding sand management 4
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INTERNATIONAL FAIRS AND CONGRESSES
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Competence in Shot Blast Technology
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