New Ways to exploit Potentials

Transkript

1 New Ways to exploit Potentials with the Lost Foam Casting Process

2 Great potentials Ready for challenging Tasks Complexity, less weight and functional integration: these are some advantages of cast parts produced in the Lost Foam Casting Process (LFP). Instead of welding together several individual parts, the components in the Lost Foam Process are cast in one piece. Due to the constant enhancement of the procedure, series production is not a problem anymore today. More and more users exploit the diverse design possibilities of Lost Foam in order to unleash completely new potentials. The reason for this is, that the LFP has proven successful in challenging tasks where other casting procedures failed or lead to an unsatisfactory result. Unique Freedoms of Design Thus, the process enables e.g. undercuts as well as finest ducts and it offers unique freedoms in designing as well as casting related, economic and ecological advantages. In the LFP cast parts can be realized in steel, cast iron, aluminium and copper alloys. On the following pages, we would like to inform you about the advantages and possibilities of the Lost Foam Casting Process. We are looking forward to further improving the process and to exploiting even more potentials together with you. Of course we would also be happy to support you in any matter. Your Lost Foam Council e. V. Team

3 The advantages Advantages and added Values at a Glance From purchasing to design to production: the Lost Foam Casting Process offers advantages for the whole process chain. Engineers, designers, technicians and buyers can profit from this. Advantages of the casting technique one burrless component instead of welded or joined individual parts hardly any machining operations and post-treatment pre-casting of drillings and channels omission of venting omission or reduction of feeders easy demolding Economic efficiency Innovative possibilities in design engineering highly complex component designing flexible integration of secondary functions reduction of material and weight undercuts and ducts no backdrafts needed high flexibility with regard to changes significant product cost advantages low tool costs, no core boxes minimal tool wear low staff requirements high function integration rapid prototyping is possible reduction of production and storage space less raw material needed due to elimination of backdrafts Environmental and health aspects low physical strain due to light patterns and low odor nuisance very low dust and noise emissions due to minimal fettling effort reusability of the molding material waiver of binders

4 Der Verfahrensablauf So funktioniert das Lost Foam Gießverfahren Phase B: Schlichten des Modells 4 5 Kennzeichnend für das Verfahren ist die Verwendung von verlorenen Schaummodellen, die im Gießprozess durch die Schmelze ver brannt werden. Dieses Verlieren des Modells gibt dem Verfahren seinen Namen. Die Modelle werden in Einzelsegmenten gefertigt, miteinander verklebt und bilden somit geometrisch höchst komplexe Gießmodelle. 4) Die Modelltraube wird durch Fügen von mehreren Modellen an ein Eingussystem erstellt. Dadurch lassen sich mehrere Bauteile mit einem Abguss herstellen. 5) Eine gasdurchlässige Schlichte dient als Trenn - wand zwischen Schmelze und binderlosem Formstoff und ermöglicht den Gas - wechsel bei der Modellverbrennung. Sie wird durch Tauchen auf die Modelltraube aufgetragen. Phase A: Herstellung des Modells Phase C: Der Gießvorgang ) Das Vorschäumen sorgt für die geringe Dichte des Modells, die eine zuverlässige Zersetzung im Gieß prozess garantiert. 2) Beim Fertigschäumen werden Modellsegmente in Formwerkzeugen geschäumt. 3) Durch Fügen (z. B. mit Schmelzkleber) wird aus Einzelteilen das komplexe Polymerschaummodell hergestellt. 6) Beim Einformen in binderlosem Formsand sorgen Vibrationen dafür, dass der Formstoff verdichtet und auch Hohlräume sowie Hinterschnitte ausfüllt. 7) Beim Gießen zersetzt die durch das Eingusssystem zugeführte Metallschmelze das Polymerschaummodell und ersetzt es detailgetreu. 8) Das Entformen ist äußerst einfach: Der Formbehälter wird entleert und gibt die fertigen Bauteile frei.

5 A comparison of processes Overview of Specifications The Lost Foam Process is also suitable for large product series. It enables the designing and casting with undercuts and finest ducts. Due to the binderless molding sand, it is mostly possible to refrain from the use of backdrafts for an easier demolding process. The process compared to other methods steel cast iron aluminium lost foam casting chill mold casting sand casting die casting wall thickness 4.0 mm, partially lower 4.0 mm, partially lower mm (partially 3.5 mm) mm mm mm tolerances (DIN ISO 8062) CT 7 CT 11 CT 7 CT 11 CT 7 CT 11 CT 8 CT 10 CT 10 CT 12 CT 4 CT 8 3-D form tolerance 0,8 1,5 mm 0,8 1,5 mm mm mm mm mm economic order quantity series starting from 500 pcs./year prototypes/component parts using milled models series starting from 500 pcs./year prototypes/component parts using milled models medium to large scale series (if need be also prototypes with using milled patterns) small to large scale series prototypes, small to large scale series medium to large scale series draft (partiell 0,5 ) pore portion same quality level as steel castings in sand casting mostly better than sand casting due to higher mold hardness 2 5% 1 3 % 4 8% 2 5% duct diameter depending on the length Ø 10 mm 100 mm long, depending on the position Ø 7 mm length, depending on the position Ø 6 mm 100 mm long Ø 10 mm 100 mm long Ø 10 mm 100 mm long No curved ducts, no undercuts surface quality roughness depths R a = µm R a = µm R a = 3 6 µm R z = R a = 8 10 µm R z = 80 R a = µm R z = R a = µm R z = 25 (depending on the mold wear) general radii R5 R5 R5 R 2.5 R 2.5 R 2.5 machining allowance 2 4 mm 2 4 mm mm mm mm mm mold service life (depending on the surface requirements) 300, ,000 foam patterns per engraving 300, ,000 foam patterns per engraving 300, ,000 foam patterns per engraving 40,000 60,000 castings 20,000 30,000 castings Al: 80, ,000 castings Mg: 200,000 castings source GussStahl Lienen GmbH & Co. KG Lovink Technocast b.v. Albert Handtmann Holding GmbH & Co. KG

6 The Lost Foam Council e. V. The Lost Foam Council Build Up and Share Expertise As a communication platform, the Lost Foam Council e. V. supports the innovative application of the Lost Foam Casting Process and offers its members numerous possibilities to build up and share their expertise. The versatility of the Lost Foam Casting Process opens up countless new possibilities and makes it the perfect complement to other casting procedures. Therefore it is all the more important to work on the exploitation of further Lost Foam potentials. For this purpose, the Lost Foam Council e. V. supports the scientific and technological development of the lost foam casting process in Europe. All enterprises and institutions involved in the process chain from the development and production of the polymer foam patterns to the completion of the metal components as prototypes, small or large series profit from this. We act as intermediary between business, industry, research and politics. As a registered association we bring together lost foam experts and foster a fruitful networking. With this approach we formulate our aspiration: We want to exploit new potentials with the innovative Lost Foam process and we want to make it an indispensable complement to other casting processes for the production of complex components. We are the first contact for the Lost Foam Casting Process, we offer regular training and further education courses, and we put you in contact with the appropriate experts on lost foam. Get to know us and our members! At you will find contact persons, detailed profiles of our members as well as further information and literature on the Lost Foam Casting Process. We are looking forward to seeing you there! Contact Imprint MSc Dipl.-Ing. (FH) Daniela Pille Expert Lost Foam Editor: Lost Foam Council e. V. Steinbrede Muenster, Germany Mobile: +49 (0) pille@lostfoamcouncil.de Board: Dipl.-Ing. R. Woltmann Prof. Dr.-Ing. M. Busse Managing Director: Dipl.-Ing. F.-J. Wöstmann Mobile: +49 (0) woestmann@lostfoamcouncil.de Concept and Design: moskito Kommunikation und Design Status: June 2015

7 Lost Foam Council e. V. Association for the promotion of the lost foam technology Steinbrede Muenster, Germany Visit us at