Innovative casting technology for thin-walled steel castings
The MAC GmbH engages once more together with Wolfensberger AG in Bauma and the foundry center of the Fachhochschule Nordwestschweiz, in research and development. In the pump industry, in high temperature applications and in many areas of engineering, there is a trend towards thin-walled steel castings. The partners want to face this trend actively to demonstrate their innovative strength. The contribution of MAC is to apply the experiences made in all fields of foundry industry. The knowledge will help to develop an innovative process until it is ready for the market.
The objective of the project, financed by Swiss “Kommission für Technologie und Innovation”, is to develop a new casting technology for thin-walled steel castings based on lost moulds. After a concept study laboratory scale experiments will be conducted. If the results are positive a pilot plant will be planed and installed. The ongoing project does not only include the conceptualisation, evaluation and development stages, but also its operational implementation, including the examination of economic efficiency of the new process.
By participating in application oriented research projects, MAC GmbH | Consulting and Engineering strengthens the competence as a reliable engineering partner for the development and implementation of advanced technologies.
Simulation-based optimization of cooling and characteristics of large castings
The MAC GmbH together with Benninger Guss AG and the University of Applied Science, Aargau, is investing into the future. Benninger Guss AG from Uzwil, Switzerland holds decades of technical experience as an iron foundry for castings up to 5 tons, MAC GmbH provides experience about optimization of casting processes to this project. The partnership is completed by the foundry-center of the University of Engineering (Hochschule für Technik). Financial support is provided by the Swiss Commission for Technology and Innovation.
Customer requirements for technologically and economically advanced large castings are increasing. The worldwide trend of near-net-shape design, special materials and shorter lead times requires a continuous development in casting processes and technologies.
The target of the project is to cut the cooling time of large sand moulded castings by half while keeping quality standards. In addition to the 1:1 development a numerical simulation program is extended to include the mould cooling function. Also the influence of the cooling on the resulting component properties is examined. The project is completed by assessing the resulting profitability when using the optimized method.
With the results of this project MAC GmbH | Consulting and Engineering once again presents itself as an engineering partner for innovative technologies.
OEM automotive, Germany
From June 2010 to April 2012 we have supported our customer intensively in its magnesium foundry with a resident engineer specialized in Mg-high-pressure-die-casting and have run a project with various topics.
Social Media Ninety Nine Ltd. (formerly CAPE Ind. Ltd.), South Korea
In spring of 2008 we started with the Concept Engineering for a large greenfield iron foundry an extraordinary large project close to Busan, South Korea: an iron foundry with an annual capacity of 165.000 t of cylinder liners to be used in 2-stroke-marine-engines. We did not only plan the foundry but we also delivered the casting technology including the gating system, form filling and solidification simulation, the pattern making, the mould design and the sophisticated grey iron metallurgy with special hard phases for wear resistant cylinder liner surfaces.
Together with our customer the detail engineering was conducted at site and in Switzerland which resulted in the first casting already in November 2008 just eight month after project start.
The project was concluded successfully in spring 2009 with the pouring of the first metallurgical flawless castings.
Picture sequence new foundry and first casting
Mahle GmbH, PC small engines
From January 2004 to August 2009 we have been involved in the planning and realization of the new automated raw castings manufacturing for small 2-stroke-motors. Our tasks included the design of the complete production lines with anorganic core manufacturing by Laempe & Mössner GmbH, Germany and the gravity casting process of Global Foundry Systems s.l.r., Italy
Gebrüder Sulzer AG, Oberwinterthur, heavy casting
We adopted the procedure for heavy castings already in our period of education and later on during our period as journeymen and then as managers. Our knowledge is not limited to moulding and casting techniques of heavy castings, but, thanks to our experiences, we are also in a position to greatly reduced the cooling times of bigger heavy castings and therefore to improve the characteristics.
Film sequence Zylinderguss
Film sequence Motorengehäuse