Foundry MFL Components Sawing and Milling Mineral Processing
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Process

Process

Development
Everybody at the foundry strives for the most efficient solution with regard to technology and economy. Ideas and demands of the customer are put into practice by our experienced engineers.
CAD as a basis for discussion and tool for simulation and pattern design.

Computer simulation
Mould filling and solidifying simulation with Procast/ESI is an important tool in development; from the customer’s drawing of the casting to the MFL product that meets the required
specifications.  

Process
In the shell-moulding process, we use metal patterns that we produce at our plant on the basis of 3D-CAD data. The patterns, together with the casting system, are mounted on
pattern plates. 

Resin coated silica sand is poured on the heated pattern plates (approx. 220°C) in the moulding machine. The high temperature makes the sand harden. Two mould halves with the thinnest possible wall thickness, which are thus extremely economic, are created by means of time/temperature control. They are as thin as shells, hence the name.

While the shells determine the outside contours of the castings to be produced, undercuts and cavities are formed by means of special components, the “cores” as they are called.
The cores are inserted in the mould halves. The two halves are glued and pressed together in a joining press afterwards.                            

The shell moulds are put into transportation containers for casting. The shells are backed with steel shot to withstand ferrostatic pressure. After casting, the moulding sand is thermally recycled and reprocessed. No foundry sand goes into landfills!


Melting process
We use two electric arc furnaces; one of them is used for high-alloy steel grades exclusively.  

                       
Heat treatment 
Heat treatment and tempering technique are central MFL know-how. We are fully equipped for air and liquid hardening and tempering.    

            
Post processing of unfinished castings 
For large volume production, we use state-of-the-art, automatic CN controlled separating and grinding machines. 


Quality assurance

We plan the quality of casting, control the quality of our process and inspect the quality of our products in strict observance of our certified QM system according to EN ISO 9001 : 2000. Code numbers are allocated to the castings and based on these numbers each casting can be allocated to a particular smeltery and heat treatment lot. Documentation of test results ensures precise traceability.




 

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