Case study NETCore® – wind power component (rotor)

From Production Manager Gerd Lorenz, HEGER GUSS | May 16, 2019

Customer opinion

Problem: The cleaning times of the component clearly exceeded the desired processing time. Using conventional feeder techniques it was not possible to achieve an improvement on the desired scale.

Challange: To reduce cutting time and throughput time for the entire component. Furthermore, the application technology of the component required side feeders on the inside, which could only be removed with great effort.

Customer

HegerGuss GmbH

Casting application

Wind power component (rotor)

Alloy

EN-GJS- 400-18

Pouring temperature

1,340 °C

Weight

9,800 kg (11,200 kg liquid)

Feeding

Top feeder and side feeders

Solution

Introduction of NETCore® breaker core technology for top and side feeders

Results

It was possible to remove the top feeders with a few hammer strokes and some even fell off at the shake-out. For the internal feeders, the gentle use of a hydraulic spreader made it possible to reliably remove the riser rest while significantly reducing the risk of scrap.

Photos and videos

Exothermic side feeder with NETCore®

Exothermic side riser (SFX) with NETCore® at the pattern

Exothermic side riser (SFX) with NETCore® after molding

Top riser with NETCore®

NETCore® top feeder after molding

A comparison of processing steps

The case study below details the time saved in the processing of castings and removal of risers through the cleaning department with and without NETCore® technology.

Without NETCore®

With NETCore®

Without NETCore®

With NETCore®

Knocking off riser rests

170 min

30 min

Total time

170 min

30 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

Hegerguss is Europe’s leading foundry in the field of serial castings for the wind power sector. Heger castings weigh up to 30 tonnes and are delivered to customers in Germany and throughout the entire world.

Download PDF

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