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SeiatSu air-Flow SqueezeMoulding ProceSS

SeiatSu... the process for producing consistently perfect moulds.

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The SEIATSU air flow squeeze moulding process is a method of compacting moulding sand. The required quantity of sand is released when the louvre shutters of the sand do-sing hopper are opened. The mould is formed by a pattern plate mounted on a pattern bolster. A guiding frame on top of the moulding box guides the sand into the box (fig. 1).

The sand dosing hopper underneath the sand storage hop-per then moves to the side and simultaneously the squeeze head moves in position over the mould. The machine table rises thus pressing the bottom bolster (including the moul-ding box and filling frame) against the squeeze head, her-metically sealing the system. The SEIATSU air flow valve is then opened. The air is passed through the moulding sand

from the back of the mould and towards the pattern. Vents provided on the pattern plate or on the pattern itself facilitate the air flow simultaneously through all the components (fig 2).

The mould is then compacted by applying pressure in an arrangement that may use a squeeze plate, an elastic squeeze plate or a multi-ram press (fig. 3). Whilst the com-pacting process is proceeding the dosing hopper is refilled.

To separate the mould and the pattern the machine table is lowered and the sand dosing hopper and the squeezing head are moved back to their datum position (fig. 4).

the process sequence.

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 mm

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After-compacting by multi-ram press Separation of pattern and mould

Mould example: Bottom Flask for a flow clutch, rib width 2.5 mm, dia. approx. 400 mm Previously made using sand cores, now with green sand mold insert. After the finishing pressure is applied an even mold is formed.

When penetrating the moulding sand the air flow results in a downward force on every grain of sand. Thus the air flow forces the sand into every recess in the mould pattern. The packing density increases in the direction of the flow, layer by layer, in such a way that the sand is most tightly compac-ted in the zones that are closest to the pattern.

To demonstrate this excellent compacting effect 35 mm high layers of sand of different colours were built up around a pattern. After the air flow was applied the thickness of the layer at the bottom was reduced to 20 mm whilst that at the top was 30 mm. With the subsequent pressing, a uniform compaction of the entire mould is achieved.

The air-flow.

Moulding sand

coloured layer

pattern

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The advantages of the SeiatSu process.

The moulds produced are uniformly hard resulting in the production of dimensionally accurate castings. The moulds produced by the SEIATSU air flow process are considerably harder than those produced by jolt squeezing.

uniformly high mould hardness.In many cases cores can be eliminated when moulding complicated pattern shapes and extreme cods with the SEIATSU process

Fewer cores required.

Draft can be reduced to 0.5° when using the SEIATSU process, resulting in corresponding reductions in use of material and in machining costs.

reduced pattern draft.The ability to reduce the distance between patterns from each other and the side of the mould results in improved utilisation of the available space and hence more castings per mould.

improved utilisation of the mould space.

0 10 20 30 40 50 60 70 80 90 100

Measuring points

Mould hardness (GF units)

Sand

hei

ght (

in m

m)

0

20

40

60

80

100

120

140

160

180

200

JoltingJolting + squeezingAirflowAirflow + squeezing = SEIATSU

Core Selfcore ingreen sand

285

Tape

r 0,

5°32

0

ø170

ø200

Jolt Squeeze Machinewith core

SEIATSUSqueeze Moulding Process

without core

100

80

60

40

20

0 10 20 30 40 50 60 70

mou

ld h

ardn

ess

distance A in mm

jolt-squeezing

air flow-squeezing

Distance A 20

78

78

85

80

–

30

82

81

85

83

50

40

84

83

85

84

62

50

85

84

86

85

68

60

85

85

88

86

72

Mean value

Mean value

Mea

surin

g po

ints

1

2

3

Jolt-squeezing

1

2

3

ø 260

250

200

A

Air flow squeeze mouldingJolt squeeze moulding

–1,2

D1

Casting weight

Maximum variation range

D2

H1

H2

mmkg –0,8 –0,4 0 0,4 0,8 1,2

D2

D1

H2 H1

Luftstrom-Press-FormverfahrenRüttel-Press-Formverfahren

–1,2

D1

Gussteil-gewicht

Maximaler Streubereich

D2

H1

H2

mmkg –0,8 –0,4 0 0,4 0,8 1,2

D2

D1

H2 H1

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The SEIATSU process achieves consistently high general and surface quality, and dimensional accuracy with almost no burrs, so that fettling requirements and machining costs are very considerably reduced.

reduction in fettling costs.

15 20 25 30

Compression resistance N/cm3

50

60

70

80

90

100

Gas

pen

etra

tion

res

ista

nce

Gd

with air current

without air current

1. Using pressure aloneporosity 29,2 %

2. Using air flow and pressureporosity 32,9 %

SEIATSU-PROCESSCasting tolerances/GTB15, DIN 1685

–3 –2 –1 0 1 2 3

L = 810 mm

B = 397 mm

H = 152 mm

Weight of casting162 kg

Where the jolt squeeze process is replaced by the air flow system noise levels are brought down to 85 dB(A). This brings a major improvement in the working conditions in a

environmental advantages.foundry. The SEIATSU process does not produce shock loads so that the foundation requirements are simplified, the impact on the surroundings is reduced and there is less need for maintenance.

Comparison of the noise emissionbetween jolting and SEIATSU

level time signal of a jolt moulding machine

(ram jolter)

level time signal of a air flow squeeze moulding machine

(open valve)

110 dB(A)

100 dB(A)

90 dB(A)

85 dB(A)

80 dB(A)

Comparison of the noise emissionbetween jolting and SEIATSU

level time signal of a jolt moulding machine

(ram jolter)

level time signal of a air flow squeeze moulding machine

(open valve)

110 dB(A)

100 dB(A)

90 dB(A)

85 dB(A)

80 dB(A)

Comparison of the noise emissionbetween jolting and SEIATSU

level time signal of a jolt moulding machine

(ram jolter)

level time signal of a air flow squeeze moulding machine

(open valve)

110 dB(A)

100 dB(A)

90 dB(A)

85 dB(A)

80 dB(A)

Dynamic load in the surroundings of moulding machines

30

Distance of the machine in m

Vib

ratio

n s

pee

d in

mm

/s

2 3 4 5 6 8 10 20 30 40

20

10

8

65

4

3

2

1

0,8

0,6

0,5

0,4

0,3

0,2

0,1

admissible range

SEIATSU moulding machine

jolt-squeeze moulding machine

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There is a SeiatSu moulding machine to suit every moulding plant requirement

Pattern-draw moulding machine (pin- or roller lifting) with pattern turntable for the production of cope and drag moulds, equipped with flat squeeze plate or water cushion. Sand filling by hopper discharge belt. Moulding box handling manually on roller conveyors or with lifting appliance. Turnkey machine with integrated hydraulic system and electronic control. Moulding box

Inside sizes mmOutput approx. compl. m/h

500 x 400 1000 x 800

4015

HSP

Lowering moulding machine with pattern turntable for the production of cope and drag moulds, equipped with flat squeeze plate or elastic squeeze plate. Sand filling by hopper discharge belt or batch hopper. Moulding box handling by hydraulic cylinders on roller conveyors. Turnkey machine with integrated hydraulic system and electronic control.

500 x 400 1250 x 1000

7020

HSP-d

Lowering moulding machine with pattern roller conveyor for the production of one mould-half each, equipped with flat squeeze plate or multi-ram press. Sand filling by hop-per discharge belt or batch hopper in front of the machine with possibility of manual inter-vention. Moulding box handling by means of hydraulic cylinder on roller conveyors.

1000 x 800 2500 x 2000

5010

daFM-Sd

Lowering moulding machine with pattern turntable for the production of cope and drag moulds, equipped with flat squeeze plate, elastic squeeze plate or multi-ram press. Sand filling by hopper discharge belt or batch hopper in front of the machine with possibility of manual intervention. Moulding box handling by means of hydraulic cylinder on roller conveyors.

500 x 400 1250 x 1000

10050

daFM-Sd

Moulding box Inside sizes mm

Output approx. compl. m/h

Moulding box Inside sizes mm

Output approx. compl. m/h

Moulding box Inside sizes mm

Output approx. compl. m/h

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Fully automatic lowering moulding machine with pattern roller conveyor and pattern shuttle truck for the production of cope and drag moulds, equipped with multi-ram press as standard equipment. Sand filling by batch hopper. Moulding box handling by means of hydraulic cylinder on roller conveyors.

1000 x 800 2500 x 2000

6020

eFa-S

Fully automatic lowering moulding machine with pattern turntable for the production of cope and drag moulds, equipped with multi-ram press as standard equipment. Sand fil-ling by batch hopper. Moulding box handling by means of hydraulic cylinder on roller conveyors.

500 x 400 1600 x 1250

14080

eFa-Sd

Fully automatic twin-type moulding machine for simultaneous production of one cope and one drag mould, with pattern roller convey-or and pattern shuttle truck, equipped with flat squeeze plates, elastic squeeze plates or multi-ram presses. Sand filling by batch hoppers. Moulding box handling by means of hydraulic cylinder on roller conveyors.

500 x 400 1250 x 1000

250160

zFa-S

Fully automatic twin-type moulding machine with pattern turntable for the production of two cope or two drag moulds or one moul-ding box pair, equipped with flat squeeze plates, elastic squeeze plates or multi-ram presses. Sand filling by batch hoppers. Moulding box handling by means of hydrau-lic cylinder on roller conveyors.

500 x 400 1250 x 1000

250160

zFa-Sd

Moulding box Inside sizes mm

Output approx. compl. m/h

Moulding box Inside sizes mm

Output approx. compl. m/h

Moulding box Inside sizes mm

Output approx. compl. m/h

Moulding box Inside sizes mm

Output approx. compl. m/h

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SeiatSu examples of grey iron casting

Electric motor housings material: EN-GJL, mass: 280 kg, 26 kg, 3,8 kg

Engine block material: EN-GJL, mass: 150 kg

Axle material: EN-GJL, mass: 680 kg

Oil cooler material: EN-GJL, mass: 28 kg

Engine block material: EN-GJL, mass: 300 kg

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Oilpan material: EN-AC, mass: 33 kg

Oilpan material: EN-AC, mass: 31 kg

SeiatSu examples of aluminium casting

Gearbox material: EN-AC, mass: 24 kg

Cage material: EN-AC, mass: 4 kg

Valve cage material: EN-AC, mass: 0,5 kg

VO

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06/1

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SeiatSu a perfect casting

Hitch cage material: EN-AC, mass: 12 kg

Exhaust cage material: EN-AC, mass: 4 kg

din en iSo 9001:2000Zertifikat: 09 100 72018

Bahnhofstraße 101 • D-57334 Bad Laasphe Tel +49 (0) 2752 907-0 • Fax +49 (0) 2752 907-280www.wagner-sinto.de

Bahnhofstraße 101 • D-57334 Bad Laasphe Tel +49 (0) 2752 907-0 • Fax +49 (0) 2752 907-280www.wagner-sinto.de

HeinricH wagner SintoMaschinenfabrik GmbH SINTOKOGIO GROUP Bahnhofstraße 101 · 57334 Bad Laasphe, GermanyPhone +49 (0) 2752 907-0 · Fax +49 (0) 2752 907-280www.wagner-sinto.de