Aeration Moulding Machine ACE
1. Functional Description 2. Test Moulding Plant GF Mettmann 3. Possibilities of Saving Energy and Cost 4. Application Spectrum
1. Functional Description
Moulding Process Molding Sequence Pattern Squeezing
Characteristics ACE Aeration sand filling Preadjustment Combined squeezing Lifting Energy saving hydr. Molding Data Analysis System sand filling optimization System Assumed sand filling weight Flask setting Moulding Metering of sand quantity Set flask setting position for next cycle Calculation of the sand quantity for the next mould
2. Test Moulding Plant GF Mettmann
ACE Test Moulding Plant HWS moulding machine ACE, flask size: 930x700x320 mm Cycle time 25.0 sec. Model year 2010 Location Mettmann (Germany)
Moulding accuracy block pattern ACE existing jolt-squeeze flask Jolt-squeeze moulding machine Shoot-squeeze moulding machine
Moulding accuracy production pattern Wheel carrier VW PQ 35 weight of raw part 5.66 kg Base support with cope plate ACE mould
Trial mould pressure measurement at pattern plate Test point 1 = centre Test point 2 = edge
Ti Trial mould pressure measurement at pattern plate Voltage [V] 10 9 8 uniform mould strength at the edge and in the middle 1,6 1,4 1,2 Distance [m mm] 7 Squeezing from 6 pattern side results in an increase of the compaction curve. 5 4 1 0,8 0,6 Pressdruck Unterpressrahme n Dig_Signal Sensor 1 Mitte 3 2 parallel separation of pattern and mould by using levelling 0,2 1 frame 0,4 0 Time [s] 4 5 6 7 8 9 10 11 12 13 14 0
Wear characteristics Specimen: wear cone Material: corpus material Sika M940 Wear: V = (weight start - weight end) ) 10,000 X density moulds [cm 3 ] Wear per 10,000 moulds 1,8 1,6 1,4 Volume [cc cm] 1,2 1 0,8 0,6 Wear cone 0,4 0,2 0 IML - Impuls PL1 - Schiesspress ACE
Dimensional accuracy of the castings Test results Type of accuracy IMC AM409 ACE S thickness dimensions i [mm] 016 0.16 015 0.15 009 0.09 DCTG grade 9 9 7 S X,Y position dimensions [mm] 0.17 0.20 0.14 DCTG grade 9 9 8 S Z position dimensions [mm] 0.15 0.15 0.13 DCTG grade 8 8 8 * S = standard deviation of a test statistic of 20 pieces DCTG grade as per DIN EN ISO 8062 relating to the averaged values and a process capability of 1.67
Conclusion of the moulding tests With the ACE moulding machine, tolerances of DCTG 9 were reduced to DCTG 8 (some dimensions even down to DCTG 7). The dimensional accuracy of the moulded copes and drags is higher than in any other tested moulding process. The mould hardness can be adjusted uniformly up to the flask edges. Moulding by using the levelling frame is very precise and exact (lifting curves with pressure sensors). Wear of the pattern plate is very low in the ACE process.
3. Possibilities of Energy and Cost Savings
Minimised hydraulic station Conventional ACE 75 kw 22 kw Flask size 900x700x250/250mm, 120 moulds/hr
Check of spraying agent Conventional method = open spraying ACE = closed spraying Requirement of spraying agent pattern pattern 40 50 med Spray Ratio (%) Consum 100 80 60 20 0 100 conventional ACE No excessive material in use Video
Less space required for the ACE Reduced size in comparison to conventional moulding machines ACE
Optimization of sand filling sand filling check Sequence of sand filling check Adjustment of sand quantity Mo old height(mm) 285 280 275 270 265 260 Target=265±5mm pattern change Setting of flask Molding Detection of sand quantity Adaptation for the next mold t(%) Sand Requirement 255 1 120 100 80 60 40 20 0 3 5 7 9 11 13 15 17 19 Number of molding 100 100 21 23 25 27 29 Cut-off Sand Spill at Molding Mold Sand Calculation of sand quantity for the next mold Conventional ACE 120 105
ECO Metals Award GIFA 2011
4. Application Spectrum
Cylinder block ACE 5 (flask size: 1050 700 300/300) Jolt Squeeze (AVS) Squeeze Pressure 60 N/cm² per area ACE Squeeze Pressure 60 N/cm² per area Casting Weight (kg) Ø = 73.8 Ø = 71.7 2.8%
Gearbox housing ACE 5 (flask size: 1050 700 300/300) Jolt Squeeze (AVS) Squeeze Pressure 60 N/cm² per area ACE Squeeze Pressure 60 N/cm² per area Casting Weight (kg) Ø = 74.5 Ø = 71.6 3.9%
Wheel carrier ACE 5 (flask size: 850 750 250/230) Free from burrs!
Brake drum ACE 4 (flask size: 850 600 280/280) Mould strength (N/cm 2 ) 20.3 17.9 22.1 22.2 18.8 24.8 18.5 20.9 21.0 23.6 24.0 25.8 19.1 17.8 23.8 23.8 17.8 24.2 23.5 21.6 23.1 Mould strength (N/cm 2 ) outside average 22.1, variation 1.3 partition ave. 24.0 deviation 1.1 cod ave. 18.3 deviation 0.5
Housings for electric motors not possible with ACE moulding machine
Summary Significantly better mould result in comparison to moulding processes of competitors, documented by tests at GF Mettmann. Potential for energy saving thanks to various features (e.g. small hydraulic station, reduction of sand requirement, less parting agent). Thereby possibility for subsidies in case of an application for investment. Excellent application possibilities in automotive industry, large-scale production. No housings for electric motors and high cods possible. The compact design is well suited for machine replacements.
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