Case study NETFrame® – Truck-Axle

Production manager | December 12, 2018

Customer opinion

Problem: A large side riser is employed having a contact area of 60 x 120 mm split along the joint line. 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.

Challenge: Removal of the feeder residue within the regular process, no movement of castings to additional cutting stations.

Application

Axle casting

Material

EN-GJS-400

Casting temperature

1.370°C

Weight

110 kg

Feeding technology

side feeder (see picture)

Solution

Integration of NETFrame ® technology „NF 1 (53×46)“ into the casting process. The NETFrame ® is placed onto the cope pattern prior to moulding within the riser contact, and against the casting surface.

Results

The riser was able to be removed by traditional mechanical methods (wedge) 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 in removing riser residues by 11 Minutes per casting. In addition it was possible to eliminate the risk for breaking in and a significant reduction in the overall casting rejection rate was achieved.

Images and videos

NETFrame®
NETFrame®

Side riser with NETFrame® after shake out

Speiserrest
Speiserrest

Sider riser with NETFrame® after knock off

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 NETFrame® technology.

 
 
Without NETFrame®
With NETFrame®
 
 
 
Without NETFrame®
With NETFrame®
Knock off of riser rest
not possible
1 min (wedger)
Taking casting out of process
4 min
not applicable
Transportation time to cutting station
3 min
not applicable
Cutting and grinding riser rests
4 min
not applicable
Return to process
1 min
not applicable
Total time
12 min
< 1 Minute

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 is one of the leading cast iron foundries in Eastern Europe producing castings for the commercial vehicle and agricultural machinery industry sectors with an annual capacity of 160,000 Mt. To optimise cleaning costs, GTP NETFrame ® technology was first trialled in 2017 and has been in serial production since 2018

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Further customer opinions

12/2018

Fallstudie NETCore® – Rahmen

12/2018

NETCore® – Rahmen

„Durch den Einsatz der NETFrame® Produkte können wir die Durchlauf- und Bearbeitunsgszeiten – speziell bei Teilen mit großen Seitenspeisern – signifikant reduzieren.“

Produktionsleiter

Fallstudie-NETCore-Rahmen.pdf (270 KB)

Download

12/2018

Fallstudie NETCore® – Lagerschale

12/2018

Fallstudie NETCore® – Lagerschale

„Durch NETCore® sind unsere Ausschusskosten durch Putzfehler um mehr als 80% gesunken.
Die Prozesssicherheit ist mit konventionellen Verfahren nicht erreichbar.“

Qualitätsstellenleiter

Fallstudie-NETCore-Lagerschale-01.pdf (198 KB)

Download

12/2018

Fallstudie NETSleeve® – Maschinenbauteil

12/2018

Fallstudie NETSleeve® – Maschinenbauteil

„Die NETSleeve®-Technologie ermöglicht uns bei diesem Bauteil die Putzkapazität um ein Vielfaches zu steigern ohne in kostenintensive Anlagen zu investieren.“

Gießereileiter

Fallstudie-NETSleeve–Maschinenbauteil-01.pdf (264 KB)

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12/2018

Fallstudie NETFrame® – Hydraulikkomponente

12/2018

Fallstudie NETFrame® – Hydraulikkomponente

„Der Einsatz der NETFrame® Technologie ermöglicht uns anspruchsvolle und putzintensive Bauteile innerhalb der regulären Durchlaufzeit zu produzieren, ohne diese aus dem regulären Produtktionsprozess ausschleusen zu müssen. Des Weiteren wird die Ausschussquote deutlich reduziert.“

Assistent d. Leitung Qualitätssicherung/
Bemusterungsbeauftragter

Fallstudie-Hydraulikkomponente-NETFrame-01.pdf (208 KB)

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