why lost foam
DESCRIPTION
Description of the Lost Foam Casting process and explanation of what makes the Lost Foam Casting Process preferable to other forms of casting techniques.TRANSCRIPT
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WHY LOST FOAM ?
Presented by Karel Cermak
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1.CASTING TOLERANCES ARE SMALLER
• DIMENSION [mm]• < 25 • 25 to 80• 80 to 125• 125 to 175• 175 to 250• > 250• Rough guide <175
>175
• TOLERANCE [+/-mm]• 0.17
• 0.25
• 0.30
• 0.43
• 0.003 per mm
• 0.002 per mm
• 0.50
• 0.80
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2.NO CORES ARE REQUIRED
• LARGE DESIGN FREEDOM
• “CONTROLLABLE” WALL THICKNESS
• NO CHAPLETS
• NO FINS
• NO MISMATCH
• NO CORE DEFECTS
• NO SAND MIX PROBLEMS
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3.NO PARTING LINES
• NO DEMOLD DRAFT
• SEVERAL LAYERS POSSIBLE
• DOWNSPRUE AND RISERS CAN BE POSITIONED OPTIMALLY
• NO MISMATCH OR FINS
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4.COMBINATION/CONSOLIDATION OF PARTS
IS POSSIBLE
• “GLUE INSTEAD OF FASTENERS”
• DECISIONS IN THE EARLY DESIGN PHASES ENABLE A HIGH ADDED VALUE TO BE ACHIEVED
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• Al-alloy ( 319 T5 )
• 11.8 kg.
• 490 x 330 x 135
• Semi-Permanent mold and cores
• Lighter
• Reduced machining
• No fettling
• Higher productivity
• Smoother
• Product performance
• Combination.
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
CYLINDER HEAD 16 V
SATURN / GM1200 PER DAY
IN-HOUSE FOUNDRY
so far 1.7 million castings produced
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• Al-alloy (319 T5)
• 18.2 kg.
• 435 x 445 x 280
• Semi-Permanent mold and cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
ENGINE BLOCK
SATURN / GM / 1.9 l / 124 PS1,200 PER DAY
IN-HOUSE FOUNDRY
so far 1.7 million castings produced
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• Al-alloy
• 22 kg.
• 600 x 300 x 400.
• Die-cast with salt cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
ENGINE BLOCK V6
MERCURY MARINE300 PER DAY
IN-HOUSE FOUNDRY
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• Al-alloy
• 12.4 kg.
• 400 x 300 x 350
• No comparison possible
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
ENGINE BLOCK V2
KOHLER OHC / 16 PS350 PER DAY
INTERMET
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OIL COOLER
IVECO300 PER DAY
ALUMINIUM DONGO
• Al 319.
• 2.5 kg.
• 250 x 150 x 30
• Semi-Permanent mold and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
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INTAKE MANIFOLD
FIAT3,500 PER DAY
ALUMINIO DONGO
• Al 319.
• ca. 5 kg.
• 280 x 220 x 50
• Semi-Permanent mold and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
so far 3.5 million castings produced
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CYLINDER HEAD
FIAT - FIRE ENGINE - PUNTO 1600 PER DAY
ALUMINIO DONGO
• Al 319.
• 12 kg.
• 370 x 140 x 120
• Semi-Permanent mold and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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INTAKE MANIFOLD
GM-OPEL CORSA1,200 PER DAY
ALUMINIUM DONGO
• Al- alloy.
• 2.45 kg.
• 260 x 220 x 190.
• Comparison difficultSand casting?
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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INTAKE MANIFOLD
FORD 2.3 l / 4 Cyl.1,200 PER DAY
INTERMET
• Al - alloy
• 5.2 kg.
• 450 x 220 x 85.
• Semi- Permanent mold and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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• Al-alloy
• 12 kg.
• 450 x 420 x 180.
• Sand casting and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
GEAR HOUSING
SAUER SUNDSTRAND220 PER DAY
WILLARD INDUSTRIES
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FMC250 PER DAY
WILLARD INDUSTRIES
• Al-alloy
• 1.04 kg.
• 139 x 125
• Comparison difficult
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
CLUSTER HUB
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• Al-alloy
• 0.7 kg.
• 90 x 90 x 32.
• Die-cast
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
HEATED COVER
XXXX1,000 PER DAY
INTERMET
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HYDRAULIC HOUSING
SAUER SUNDSTRAND210 PER DAY
WILLARD INDUSTRIES
• Al- alloy
• 13 kg.
• 350 x 200 x 200.
• Sand casting and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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• Al-alloy
• 2.8 kg.
• 350 150 x 150.
• No comparison possible
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
SUCTION PIPE
MERCEDES BENZ200 PER DAYHANDTMANN
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ALUMINIUM FAILURES
• Wrong product choice
• Reluctance to adapt design
• Underestimation of development costs
• Inexperience
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• Al-alloy
• 0.78 kg.
• 190 x 170 x 130.
• Semi-Permanent mold and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
SUPPORT/CARRIER
FLOP 1
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• Al-alloy
• 5.1 kg.
• 300 x 300 x 310
• Semi-Permanent mold and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
CYLINDER HEAD
FLOP 2
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• Al-alloy
• 1,1 kg.
• 110 x 220
• Welded part
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
EXHAUST PIPE
FLOP 3
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DUCTILE IRON• PROs
– No fixed mold process available - very good accuracy
– All parts, like for Al, pourable
– Cleaning room cost savings greater than for Al
– Environmentally cleaner than sand casting processes
• CONs– The process is
sensitive to uncontrolled carbon pickup
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• GGG 60 ( US 0.7060)
• 11.34 kg.
• 450 x 200
• Mask tool & 9 cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
CRANK SHAFT
SATURN / GM1,200 PER DAY
IN-HOUSE FOUNDRY
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• GGG 50 / 60
• 4.2 kg.
• 150 x 140
• Sand casting with cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
DIFFERENTIAL CASE
SATURN / GM1,200 PER DAY
IN-HOUSE FOUNDRY
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• GGG 40
• 11.1 kg.
• 250 x 200 x 160
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
SPRING HANGER A
VOLVO - GM HEAVY TRUCK240 PER DAY
CITATION FOAM CASTING COMPANY
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SPRING HANGER B
VOLVO - GM HEAVY TRUCK240 PER DAY
CITATION FOAM CASTING COMPANY
• GGG 40
• 13.4 kg.
• 280 x 200 x 160
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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• GGG
• 12.3 kg.
• 400 x 250 x 160.
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
CLAMP GUIDE
XXXXX200 PER DAY
CITATION FOAM CASTING COMPANY
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• GGG 40
• 5.9 kg.
• 260 x 230 x 220.
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
SUPPORT / CARRIER
MERCEDES BENZ, COMPR. MOTOR120 PER DAY
CITATION FOAM CASTING COMPANY
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DUCTILE IRON FAILURES• Wrong product
choice
• Reluctance to adapt design
• Underestimation of development costs
• Inexperience
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• GGG !!!
• 2.0 kg.
• 280 x 300
• Sand casting & 4 cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
STATOR FRAME
EXPERIMENT
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• GGx-highly magnetic
• 0.8 kg
• from 80 to 140 mm x 70
• No comparison possible
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
EL.-MAGN. CLUTCH FOR CAR A/C - ROTOR
EXPERIMENT
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GRAY IRON
• Thinner hard iron surface
• More even solidification– Reduced stress
• Quicker machining
• Increased machine tool life
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• GG
• 10 - 80 kg
• up to 800 x 1000
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
STATOR FRAMESIEMENS, ABB, BALDOR, DIEZ
CA.1000 PER DAYCITATION FOAM, VSETIN
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ELECTRIC MOTOR END SHIELD
BALDOR40 PER DAY
CITATION FOAMS
• GG
• 12 kg.
• 400 x 100
• Sand casting and cores
• Lighter
• Reduced machining
• Less fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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• GG 25.
• 4.5 kg.
• 360 x 200 x 130.
• Sand casting
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
WATER INLET / COMPONENT BRACKET
CUMMINS ENGINE CO180 PER DAY
CITATION FOAM CASTING COMPANY
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• GG 40
• 22 kg
• 600 x 300 x 100.
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
EXHAUST MANIFOLDMERCURY INBOARD
120 PER DAYCITATION FOAMS
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• GG
• 10 kg.
• 280 x 350 x 220
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
COOLING WATER PUMP
DETROIT DIESEL120 PER DAY
CITATION FOAM
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• GG
• 22 kg.
• 300 x 400 x 400
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
WATER VALVE BODYM & H NW 15080 PER DAY
CITATION FOAMS
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• GG
• 53 kg.
• 550 x 225 x 100.
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
CYLINDER HEAD - DIESEL
JIN HONG400 PER DAY
IN-HOUSE FOUNDRY
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ELECTRICAL MOTOR END SHIELD
80 PER DAYCITATION FOAM
• GG
• 26 kg.
• 711 x 120
• Sand casting with cores
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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STEEL CASTINGS
• High accuracy• Good surface quality• Also 3 + mm wall
thickness possible• Reduced machining• Increased machine tool
life• Reduced cleaning room
costs• Complicated castings
possible
ADVANTAGES LIMITATIONS
• Alloys with C < 0.15 %
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• GS - Heat resistant
• 1.2 kg.
• 180 x 200 x 30.
• Furan Sand
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
ANCHOR CLUSTER
EXPERIMENT
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“DRILL HOOK”
PAALS2,000 PER YEAR
GUSSTAHL LIENEN
• GS 25CrMo4
• 1.6 kg.
• 150 x 100
• No comparison possible
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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WATER COOLED GRATING BODY
NOELL5,000 PER YEAR
GUSSTAHL LIENEN
• GX 40CrNiSi27-4
• 32 kg
• 650 x 260 x 100.
• Furan Sand
• Lighter
• Reduced machining
• Reduced fettling
• Higher productivity
• Smoother
• Product performance
• Combination
– Fewer parts
• Less leaks
• Reduced machining
• Fewer fasteners
• Reduced assembly
• Fewer seals
• Tooling costs
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CERMAK ENGINEERING PFAHLER STR.21,
65 193 WIESBADEN, TEL.+49 611-1509 9495 E-Mail : [email protected]
PLEASE ENQUIRE ABOUT OUR PRESENTATION PART 2
“HOW IS LOST FOAM CONTROLLABLE?”