Case study NETCore® – Frames

From Managing Director Thomas Windisch, EISENWERK GmbH ELTERLEIN | March 20, 2020

Customer opinion

Problem: A riser is employed having a contact area of 80mm. Due to the size of the contact it is not possible to remove the riser with traditional mechanical means safely without risk of the contact breaking into the casting, meaning that the casting must be transported to a separate work area for riser removal by cutting.

Challange: Removal of the feeder residue within the regular process, no movement of castings to additional cutting stations and without risk for the riser contact breaking into the casting surface.

Customer

Eisenwerk GmbH Elterlein

Casting

UT Frame casting

Material

EN-GJS 500-7

Casting temperature

1.350 °C

Weight

1.027,5 kg

Feeding technology

Thermo riser with traditional breaker core

Solution

Integration of the GTP NETCore® technology in combination with the standard Thermo riser. Type: TGC 24000 B80 NR25

Result

The riser was able to be removed easily in process without the need for cutting. It was not necessary to remove the casting to a separate work area resulting in a significant reduction in the amount of labour involved (8 minutes, equals 80%)in removing riser residues. The riser removal utilising GTP NETCore® Technology eliminated the risk for breaking in and a significant reduction in the overall casting rejection rate was achieved.

Images and videos

NETCore® breaker core after moulding

THERMO Riser with NETCore® breaker core before moulding

Breaking point

Cleaning costs in comparison

The following case study describes the time saved in producing the castings and removing the riser by the cleaning department with and without NETCore® technology.

 
 
Without NETCore®
With NETCore®
 
 
 
Without NETCore®
With NETCore®
Transportation time to cutting station
3 min
not applicable
Positioning of the casting
1 min
not applicable
Knock off
4 min
> 1 min
Grinding
2 min
1 min
Return to process
2 min
not applicable
Total time
12 min
> 2 min

Advantages at a glance

Reduced cleaning costs
Less scrap
Knock off up to 450 mm
Significant time savings
Reduced risk of injury

Download case study

Our customer Eisenwerke Elterlein is a hand moulding foundry specialising
in the production of grey and nodular iron castings for general mechanical
engineering, special machine tool construction, gear construction, printing and agricultural machinery sectors in weights up to 5 tons. In order to improve
processing times GTP NETCore® Technology was introduced in 2017 and is used as a replacement for conventional feeder technology where removal of risers and associated cleaning cannot be reproduced reliably and efficiently.