Conventional wisdom in the foundry industry has given way to a new order with the arrival of the New Generation of DISA moulding machines. Vertical moulding technology has undergone a paradigm shift and is even making inroads into what used to be the realm of horizontal moulding and even die casting. The result is higher speed, quality and reliability, and significant enhancements to the working environment within the foundry.
The New Generation of DISA moulding machines started with the presentation of the DISA 230 at GIFA in 1999. Since then, the DISA 230 has set new standards in high-quality, cost-effective production of complex shapes.
The documented reliability, superb accuracy and optimised mouldability of this new, vertical greensand moulding technology led quickly to customer demands for larger mould sizes. The family was extended with the DISA 240 and 250 offering mould sizes of up to 650 x 850 x (150-500) mm. The next addition, the DISA 280 with a mould size of 850 x 1200 x (250-675), was presented at GIFA 2003 and offers mould sizes that are able to compete with horizontal moulding machines. Since then, the DISA 270 with a mould size of 700 x 950 x (200-650) has been added to fill the gap between the DISA 250 and DISA 280.
Heir to the DISAMATIC
Many existing DISA customers have decided to replace an existing older machine such as the DISAMATIC 2013 with the equivalent New Generation machine. The reason is simple enough. Technology has progressed in leaps and bounds, offering greater process control and greater precision with less need for maintenance.
A simple cost of ownership calculation shows that the New Generation makes significant savings in operating costs already in the first year in comparison with a machine of equivalent capacity, while also enabling the production of higher quality castings with less scrap. At most foundries that adds up to increased market share through higher quality and competitiveness and higher profits due to lower costs.
Knocks horizontal moulding flat on its back
Just a few years ago, conventional wisdom taught that vertical moulding technology had an upward limit as far as mould size was concerned. That may be true, but the limit has not yet been reached. DISA is constantly pushing up the limit and the latest addition to the New Generation family, the DISA 280, offers a huge 850 x 1200 x (250-675) mm mould size, enabling it not only to compete with but to beat comparable horizontal moulding machines on virtually all counts:
- Speeds of up to 300 moulds an hour for uncored moulds and 280 moulds an hour for cored moulds mean the DISA 280 leaves horizontal moulding panting to keep up.
- A machine-dependent mismatch of only 0.20 mm or less means precision of a kind that horizontal moulding finds it hard to match.
- Standard double squeeze operation ensures consistently high mould stability even in the biggest mould sizes with consequent lower scrap and no or little requirement for fettling.
- Separate main pump units for both the pressure plate and swing plate put the DISA 280 into overdrive as far as capacity is concerned.
And just to make things as easy as possible, 98 per cent of existing tools can be reused on DISA’s New Generation moulding machines. A number of foundries such as Valdemar Birn in Denmark, a jobbing foundry, and Leda in Germany making stove parts, have taken advantage of the competitive edge of New Generation moulding machines from DISA to replace existing machines.
Heavyweight solutions for lightweight cars of the future
Perhaps one of the most exciting aspects of the New Generation is its combination with Active Filling for the production of high-integrity aluminium castings.
Aluminium is especially interesting for the automotive industry in its bid to increase fuel efficiency by saving weight. Wheel rims, chassis and exhaust manifolds and even engine blocks are examples of automotive parts that are increasingly being made out of aluminium. And automakers are constantly looking for opportunities to cut costs, for example by using all-in-one castings that eliminate labour-intensive assembly of components.
Quality demands, however, are rigorous with regard to cracking, elongation and collapsibility. This imposes demands on the casting process requiring an exceptionally high degree of precision and integrity.
Bréa introduces a new French revolution
The mould stability and precision of the New Generation from DISA means that many aluminium automotive components can now be made on these machines. The Bréa foundry in France is an example where a DISA 230-C with a mould size of 500 x 675 x (120-395) mm has now been producing exhaust manifolds for automakers such as Renault and Peugeot for more than two years.
According to Bréa, the DISA 230-C consistently performs at 320 moulds an hour with extremely low scrap rates.
Automotive components and new alloys
Another automotive application in which the DISA 230 has proved its worth is the production of brake components in high-carbon iron. A leading automaker in the UK chose the DISA 230X because of its completely redesigned mechanical, electrical and hydraulic systems providing new standards of accuracy, optimal mould stability, production capacity and reliability.
Intercast & Forge in Australia and Intat in the USA are other examples of foundries making automotive parts who have begun to reap the benefits of the New Generation from DISA, both with new DISA 240 moulding machines.
Good for the environment, good for physical health...
Compared to other processes, the DISA New Generation is an environmental dream, with substantial savings on energy. The hard physical effort and noise associated with conventional moulding systems are virtually eliminated and modern process control systems mean that operator intervention – and the risk if error – is cut to a minimum. And with its much smaller footprint compared to horizontal moulding machines, the New Generation takes up less space in already crowded foundries.
...and good for business
The main thing, however, is still the need to produce profitable castings at a competitive price. In the intensely competitive foundry industry of today, the DISA New Generation is demonstrating how technology development based on the real needs of customers can help foundries boost their earnings and achieve even better return on their investment.