DISA FLEX

DISA FLEX is a horizontal flask moulding machine, manufactured using Swiss proven technology the technology is designed for foundries wanting a flexible solution for production of high quality, medium and heavy near net shape castings 

DISA FLEX combines the unique DISA high pressure, double-blow and hydraulic squeeze moulding technique with a rigid machine design, giving the best conditions for the profitable production of high quality castings on a horizontal greensand moulding machine.

 

DISA FLEX - horizontal flask moulding machine

Moulding:

101 - 150 moulds per hour

Výhody

Optimum casting quality due to high pressure, uniform mould compaction

Constant and lower casting weight - Near net shape castings for less cleaning

Full utilisation of the pattern plate due to better compaction of pattern areas located close to the flask wall

Production reliability through high repeatability

Variants

DISA FLEX moulding machine produces up to 120 moulds per hour and it comes in 3 different variants:

  • DISA FLEX 70 HS: 800-1000x700x200-325
  • DISA FLEX 80: 900-1050x800x250-350
  • DISA FLEX 90: 1000-1300x1000x250-400

Application

  • Casting weight: Above 20 kg
  • Alloys: Grey/Ductile/Simo Iron
  • Typical castings: Automobile castings, Engine blocks, Brake drums/discs, Tractor housing,Compressor housing, Camshafts and Pumps
 

Features that make the difference

  • Reliable machine with automatic mould handling system
  • Operator friendly and easy maintenance
  • Upgrade feasibility plan with less initial investment
  • Computer Integrated manufacturing (CIM Modules)
  • Remote monitoring systems (RMS)

When we had a requirement for foundry solutions at MAHLE, we immediately turned to DISA. DISA’s ability to develop highly customised and complete foundry solutions made it a perfect fit for our project. The quality of products, work and people is unparalleled – DISA understands today’s need for fast, reliable results and works well with our team to help us deliver world-class products to our customers. We continue to rely on DISA’s impeccable expertise and in-depth understanding of the Indian market, not to mention its excellent service, time and again. We look forward to our continued relationship with DISA.

Pradeep Bhatia, Managing Director, MAHLE Engine Components India Private Limited.

DISA FLEX - Horizontal flask moulding line

Flask turn-style moulding machine, designed for foundries wanting a flexible solution for production of high quality, medium and heavy near net shape castings

Mould Handling System (MHS)

The DISA MHS protects the mould integrity through perfect synchronisation with the DISA FLEX machine.

The system consists of a moulding line for automatic sprue drilling and core setting, rollover devices, closer with clamping devices, transfer cars and a cleaning station in addition to cooling lines, a punch-out station and an automatic flask separator.

The separating unit

The DISA FLEX moulding line starts with a separating unit setting the cope and drag flask on the moulding line. The emptied flask pair along with pattern plate will be transferred to Mould conveyor and lifted up to separate it from pallet. meanwhile gripper unit moves up/downwards to separate the cope & drag flask and transfer to the moulding machine.

Unit cleaner

Before the flasks move into the moulding machine special units clean the flask inside, the flask top surface, pin, bushes and checks the flask top surface for melt pearls burnt to the top surface. This feature ensures the smooth operation of the line and helps to improve mould quality. After the moulding machine, the excess sand on the mould back side is removed by a heavy duty sand cutter.

Rollover devices

The rollover devices are specially designed to avoid sand spill on the mould. The motor drive is on the top of the station for easy service access.

Drilling station

DISA offers both a low cost pouring cup drilling station, where the position is set manually by the operator or an automatic drilling station where the pouring cup position is set automatically by data from the control system. For high production lines DISA offers fully automated vent hole drilling stations and core setting stations.

Flask closer

The flask closer is a very important unit. The cope flask is set on the drag with high precision, due to heavy guide rods and active position units of both cope and drag flasks. This ensures that the mould halves go together without distortion of sand and cores.

Transfer station

The finished moulds are handled by transfer stations with reliable frequency inverter drives which ensure good motion control and a long service life.

Cooling lines

The cooling lines are equipped with robust hydraulic push and breaking cylinders for good control of acceleration and de-acceleration to ensure the safe handling of moulds.

Punch out

A very robust mould punch out completes the system. The mould is punched out from the lower side, so the mould is pushed up. This gives a safe handling of the castings on their way to the shake-out. By lifting up the moulds the shake-out can be positioned on floor level for easy operator access to the castings.

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