Case study NETSleeve® – machine component

Production Manager | May 05, 2019

Customer opinion

Problem: A variety of mini-risers are used to produce castings with modulus ranging from 1.9 to 3.2 cm without breaker cores and with contacts from 40 to 65 mm. Due to the size of the contact, it is not possible to remove the riser with traditional mechanical means, forcing the foundry to adopt a lengthy cutting process.

Challenge: To efficiently remove the feeder residue by simple mechanical methods and eliminating the lengthy cutting process, allowing the customer to increase the number of castings processed per shift.

Customer

Kundengießerei (hand-molding shop)

Application

Compressor cover casting

Material

EN-GJS-400 LT18

Casting temperature

1,380 °C

Weight

135 kg

Feeding technology

Thermo risers with modulus 1.9 (x4), 2.1 (x9) and 3.2 (x2) cm

Solution

Replacement of traditional risers with NETSleeve® TGC 810o N15, TGC 990o N15, and TGC 2329o N20.

Results

It was possible to remove the riser using traditional mechanical methods (hammer), without the need for cutting within a very short time, reducing the cutting and grinding times to a minimum. The foundry was able to increase the output per shift from 3 castings to 6 castings, due to the optimization of cleaning by the use of GTP NETSleeve® technology.

Photos and videos

Case Study ERKUNT NETSleeve®

NETSleeve® on pattern

NETSleeve® after molding

Blasted component

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  NETSleeve® Technology.

 
 
Without NETSleeve®
With NETSleeve®
 
 
 
Without NETSleeve®
With NETSleeve®
Knocking off of riser rest
not possible
2 min
Cutting time
20 min
not applicable
Grinding riser rests
10 min
5 min
Total time
30 min
7 min

Advantages at a glance

Reduced cleaning costs
Rejects reduction
Teeing up to 450 mm
Clear time savings
Decreased risk of injury

Download case study

The customer is one of the leading cast iron foundries in Turkey, producing castings for the automotive, agricultural, and construction industries with an annual capacity of 60,000 Mt with both machine and hand molding. To optimize cleaning costs and improve efficiency, GTP NETSleeve® technology was first trialled in 2017 and has been used in series production since 2018.

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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 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