Case Study NETCore® – HSI scar

From Production Manager Markus Wellewill, FOUNDRY HEUNISCH | March 12, 2020

Customer opinion

Problem: Due to the large number of risers, the separation of the feeder residues is a very expensive process. In addition, there is the risk of breaking into the casting while knocking off. In the current state, it is necessary to partially remove the risers and the remaining riser attachment is subsequently reworked separately.

Challange: To reduce the work of separation and either reduce or completely avoid riser residues.

Customer

Foundry HEUNISCH

Casting

HSI scar

Material

EN-GJS 500-7

Weight

7.900 kg

Model design

1-hand modell

Power supply technology

2 x ZRF 12 B150 NR40

Solution

Integration of NETCore® Technology at a fiber feeder

Result

By using NETCore® technology, the cast part can be produced with less time spent in the cleaning room. This enables the foundry to reduce the processing time by 30 minutes per casting or 98%. The riser residue can be removed by mechanical means. In addition, the risk of rejects due to break-in is eliminated.

Images and videos

NETCore® molds before casting (top box)

NETCore® casting before cleaning process (riser residue knocked off)

NETCore® separating surface feeder residue

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®
Knock off feeder
not possible
5 min
Removal from process chain
not applicable
not applicable
Transport to the sawing station
5 min
not applicable
Clamping saw
not applicable
not applicable
Sawing
30 min
not applicable
Return to process
not applicable
not applicable
Total time
35 min
5 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

Foundry HEUNISCH is a family-run foundry group based in Bad Windsheim.
A hand molding shop in Steinach, Thuringia belongs to this group. In 2018, the NETCore® technology was introduced to us, and after testing, we have adopted it as standard in our process.

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Further customer opinions

05/2019

Case study NETFrame® – hydraulic casting

05/2019

Case study NETFrame® – hydraulic casting

„By using the NETFrame® technology we are able to significantly reduce our processing times for demanding castings that traditionally have extended cleaning times.“

Christian Zouplna
Foundry Manager

05/2019

Case study NETSleeve® – machine component

05/2019

Case study NETSleeve® – machine component

„Since the application of NETSleeve® technology into our hand moulding process the ease in which large castings pass through the cleaning department has improved, with time the time taken for riser removal considerably reduced, this has allowed us to increase the throughput of castings by 100%“

Production Manager

05/2019

Case study NETCore® – wind power component

05/2019

Case study NETCore® – wind power component

„With NETCore®, we can reliably feed particularly difficult-to-access feeder positions and also significantly improve cleaning times and results.“

Gerd Lorenz
Production Manager HEGER GUSS