CPT International 01/2019

More documents

Recommendations

Info

Reports and product news on GIFA 2019 in CASTING PLANT & TECHNOLOGY (CP+T) Free-of-charge! It’s time again in Düsseldorf, from 25 - 29 June 2019: the foundry sector once more presents itself as a high-tech industry. We look forward to your press releases and specialist reports for GIFA 2019! PHOTO: FOTOLIA e-mail address: redaktion@bdguss.de We would be pleased to receive questions by phone: Contact: Robert Piterek e-mail: robert.piterek@bdguss.de Tel.: +49 (0)211 6871-358 More than 2,000 exhibitors from over 30 countries are expected at the 14th GIFA international foundry trade fair with WFO Technical Forum. In the News section, among other places, the editorial staff at CP+T will report on innovations, new products and new technical processes in advance of GIFA. Please send press releases and specialist reports for GIFA 2019 to the editorial office via e-mail under the heading “GIFA 2019”.
sand-binder mixture is achieved and the operation phase (B) can begin. After emptying the test material from the permanent mold cavity(s), the two halves (or more parts) of the core box are closed again and the sand-binder mixture is shot into the mold, as in conventional processes. Once the shooting process is finished the curing/hardening process can start. Due to the almost equally specific resistances, the electrical current flows homogeneously through the sand core. The sand-binder mixture thus quickly reaches a temperature of between 100 and 130 °C. The evaporation of the water during the hardening process leads, as described above, to a reduction of the free charge carriers, which in turn leads to an increase in the specific resistance in the mixture and a decrease in the electrical current flow within the sand core. Any potentially required residual heat for complete hardening of the core can be supplied to the sand-binder mixture via the mold, as in previous processes. In concrete terms: If a sand-binder mixture with a required operating temperature of 170 °C is shot into the mold at a temperature of 20 °C, approx. 2/3 of the required 150 °C is achieved by resistance-induced heating and the remaining part is supplied from the mold via heat transfer to the sand core. After hardening, the molding boxes are opened as in existing processes, the sand core removed and the next cycle initiated. For cooling phase (C), the empty core box halves are then simply moved apart and remain in this position to cool down. Advantages of the new method Multiple advantages have been identified during the course of the preliminary investigations. The potential for the new technology is expected to reduce cost and energy consumption by 33 % while increasing the speed to manufacturer the sand cores. Additional quality benefits are expected from the fact of the homogeneous sand core hardening/curing that prevents a shell formation. Furthermore can the new process improve the quality defect cost as each individual sand core can be analyses based on temperature increase, energy consumption and time. The application of six sigma approach then allows to provide a quality assessment during the curing process with the possibilities to mark or remove sand cores that deviate the from the standard process. New sand core applications are possible as much bigger sand MOLD AND COREMAKING cores could be formed efficiently as the center of the cores are also cured fully. Various inorganic binders typically used in industry have also been successfully tested so that completely new formulations are not necessary and existing binder systems can be used. The core box molds can use various materials such as silicon carbide ceramics. Ceramic molds offer a longer life cycle due to reduced wear and tear driven. Furthermore could external heat generators be eliminated as the heat is generated directly inside the sand core. A side benefits will be that family core boxes with multiple cavities would allow the replacement of individual defect cavity molds in less then 3 minutes by using quick change system. The strongest benefits versus conventional processes are foreseen for large sand cores and sand cores with a high annual volume. In direct comparison with conventional processes, the new process is all in all showing significant cost saving potentials. The savings are essentially the result of two circumstances: Firstly, the direct use of electrical current, which does not have to be converted into heat externally, results in up to 33 % higher energy efficiency compared with conventional processes. On the other hand, cycle time savings of up to 30 % of the time are expected, whereby the annual operating costs can be massively reduced. Outlook There is a high potential for this new process to sustainably increase efficiency in the production of lost cores. The basic feasibility studies as well as the testing on a prototype scale have been completed and preparations are completed for testing under near-series conditions with real-cast sand cores. The aim of the qualifications are to demonstrate the benefits at mass production scale and to allow a meaningful comparison with current processes. In this context new foundry partners are constantly wanted to assess the benefits of the new process. www.advanced-core-solutions.com Wolfram Bach, inventor of the process, “Advanced Core Solutions”(ACS) , Soplain GmbH, Welsleben, Germany, and Eric Riedel, University Magdeburg, Institute of Process Technology and Quality Management, Department of Casting and Forming, Germany from 760 € TechnologyHot. Innovative Infrared Also interested in really fast, rugged, light, accurate, configurable and inexpensive pyrometer models? Or in infrared cameras? Visit www.optris.global There’s no two ways about it: our non-contact infrared thermometers can measure temperature in ranges from –50 °C all the way up to +3000 °C. 01.04.-05.04.2019 Visit us in hall 11, stand A61.
Page 3 and 4: EDITORIAL Foundry technology made i
Page 5 and 6: CONTENTS CLEANING, FETT- LING & FIN
Page 7 and 8: “Naturally, our employees are cen
Page 9 and 10: “The share of hybrid drives will
Page 11 and 12: FOUNDRY - A PASSION FROM OUR HEART.
Page 13 and 14: COMPANY Managing Director Björn Pl
Page 15 and 16: The iron foundry was able to ensure
Page 17 and 18: CLEANING; FETTLING & FINISHING Proc
Page 19 and 20: The castings receive an individual
Page 21 and 22: 3 1 5 6 4 7 7 12 6 11 10 9 8 5 4 2
Page 23: able material for the permanent mol
Page 27 and 28: MOLD AND COREMAKING Focal point fur
Page 29 and 30: 3-D-PRINTING Fortunately, relying o
Page 31 and 32: CASTING Special GIFA 2019 Part 1: O
Page 33 and 34: SPECIAL: GIFA 2019 International me
Page 35 and 36: lished companies vulnerable - even
Page 37 and 38: The possibilities offered by 3-D pr
Page 39 and 40: among 3-D printing manufacturers in
Page 41 and 42: NORICAN GROUP Demonstration of “C
Page 43 and 44: The new technical journal WE ACCOMP
Page 45 and 46: Figure 1: The pressure sensors are
Page 47 and 48: By means of UV disinfection treatme
Page 49 and 50: RECYCLING Figure 1: During the prod
Page 51 and 52: The common heat applications in the
Page 53 and 54: completely new territory, „since

CPT International 01/2019

Create successful ePaper yourself

Delete template?

Save as template?