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DISAMATIC – Green sand Casting

Features

An advanced DISAMATIC 231 typeX molding machine is used in the green sand manufacturing process. In the green sand process, stabilization of the mulled sand is achieved by sprinkling the return sand from the casting process with water for a time in a drum cooler, adjusting the moisture content to approximately 2.0% in a mixer with water addition, and compacting the return sand for about 2 hours under an 80 ton sand-pin device. Fluid dynamics/solidification simulations are actively used in the gating system to ensure production in the optimal condition.

Manufacturing process

Manufacturing process

1 Using steel scrap material, thoroughgoing composition management is performed by spectrometry analysis. To cope with the high speed of the molding machine, molten metal is tapped via a holding furnace.
2 Molding: Molding is performed using a high-speed, vertical, flaskless, automatic DISAMATIC molding machine made in Denmark. 100% of the green sand is recycled. Production centers on products with complex cores.
3 Casting: All casting is performed by automatic. This process is supported by strict temperature control and the uncompromising techniques of skilled workers.
4 Mold shakeout: Shakeout is the process of separating the product from the mold and gating system. After separating and cooling the product and green sand in a drum-type cooler, shakeout of the product and gating system is performed with a gatepecker.
5 Shot-blast: Green sand adhering to the product surface is removed by shot-blasting with steel balls in a shaking-type continuous shot-blast machine.
6 Finishing: Using a double-headed grinder or automatic grinder, weirs and separation burr (fins where the mold was separated, etc.) are removed to within the standard values.
7 Inspection of external appearance: Visual inspection of all products is performed based on the inspection manual and limit standard manual. Products with complicated shapes are inspected using a fiberscope.
8 Heat treatment: Self-annealing (SA) is the basic heat treatment process. Depending on the product, strain relief heat treatment may also be performed by a cooperating maker.
9 Shipping: All products are packed considering corrosion prevention, dust prevention, and cushioning. Products are then shipped by dedicated carriers serving each area, and are delivered to the customer on the designated date.

Product introduction

Product introduction

Product name Differential case Turbine housing
Material FCD550 HI-SI-FCD
Material unit weight 1.2kg~3.8kg 1.5kg~7.8kg
Product name Bearing housing Hub carrier
Material FC250 FCD450
Material unit weight 0.8kg~3.8kg 0.6Kg~2.0kg
Product name Cylinder sleeve Bearing cap
Material PV-FC FC250
Material unit weight 0.6kg~3.0kg 0.6kg~1.5kg
Product name Gear case
Material FC250
Material unit weight 8.0kg~13.8kg

 
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