Castomech Technology LLP

Kalol, Gandhinagar, Gujarat

A pattern is made frompolystyrene foam, which can be done by many different ways. For small volume runs the pattern can be hand cut or machined from a solid block of foam; if the geometry is simple enough it can even be cut using ahot-wire foam cutter. If the volume is large, then the pattern can be mass-produced by a process similar toinjection molding. Pre-expanded beads of polystyrene are injected into a preheated aluminummoldat low pressure. steamis then applied to the polystyrene which causes it to expand more to fill the die. The final pattern is approximately 97. 5% air and 2. 5% polystyrene. Pre-made pouring basins, runners, andriserscan behot gluedto the pattern to finish it.^[1]

next, the foam cluster is coated with ceramic investment, also known as therefractorycoating, via dipping, brushing, spraying or flow coating. After the coating dries, the cluster is placed into a flask and backed up withun-bonded sandwhich is compacted using a vibration table. The refractory coating captures all of the detail in the foam model and creates a barrier between the smooth foam surface and the coarse sand surface. Secondly it controlspermeability, which allows the gas created by the vaporized foam pattern to escape through the coating and into the sand. Controlling permeability is a crucial step to avoid sand erosion. Finally, it forms a barrier so that molten metal does not penetrate or cause sand erosion during pouring. Once the sand is compacted, the mold is ready to be poured. Automatic pouring is commonly used in lfc, as the pouring process is significantly more critical than in conventionalfoundrypractice.

there is no bake-out phase, as for lost-wax. The melt is poured directly into the foam-filled mold, burning out the foam as it pours. As the foam is of low density, the waste gas produced by this is relatively small and can escape through mold permeability, as for the usual outgassing control.

advantages and disadvantages

this casting process is advantageous for very complex castings that would regularly requirecores. It is also dimensionally accurate, maintains an excellent surface finish, requires nodraft, and has no parting lines so noflashis formed. The un-bonded sand of lost foam casting can be much simpler to maintain than green sand and resin bonded sand systems. Lost foam is generally more economical than investment casting because it involves fewer steps. Risers are not usually required due to the nature of the process; because the molten metal vaporizes the foam the first metal into the mold cools more quickly than the rest, which results in naturaldirectional solidification. foam is easy to manipulate, carve and glue, due to its unique properties. The flexibility of lfc often allows for consolidating the parts into one integral component; other forming processes would require the production of one or more parts to be assembled.

the two main disadvantages are that pattern costs can be high for low volume applications and the patterns are easily damaged or distorted due to their low strength. if a die is used to create the patterns there is a large initial cost.

Features:

• Robust design to handle the advance condition of foundry requirement.
• User-friendly HMI touch display operation.
• Ensures uniform production quality with minimum and easy calibration.
• Permits to cover the large circular span for mould box filling.
• Available with a motor-driven variant.
• Attains all benefits of SINGLE-ARM CONTINUOUS MIXER.

Features:

• Used for unloading of sand through tilting device.
• Operates on the hydraulic system and can be merged with the hydraulic power pack.
• Perfect positioning of Hydraulic pushing cylinders ensures perfect tilt angle and smooth, efficient operation.
• Unique Design allows sandbox for smooth incoming and outgoing.
• Fully Automatic due to sensors and hydraulic system.
• Hood provided on the top of the machine ensures the perfect unloading.

Features:

• 40% less intensive power consumption compared to other mixers.
• Ease of maintenance due to the drive mechanisms (motor, fluid coupling, gearbox, etc.) mounted on the top of the machines.
• Ceramic liners in the Drum and Tungsten carbide blade ensures longer wear life compared to others.
• Mixing quality is very good due to mixing blade arrangement in aid to homogenise the mixing.

With an objective to fulfill the ever-evolving demands of our clients, we are engaged in offering a wide assortment ofNo Back CO2 Sand Reclamation Plant.

We are successfully meeting the varied requirements of our clients by providing the best quality range ofGreen Sand Reclamation Plant.

Fully Automatic due to sensors and hydraulic compaction system.

Features:

• Bucket Elevator Suits the best for medium to High flow-rates for the vertical elevation of the bulk material.
• Provided with the tensioning arrangement at the bottom for the ease of maintenance.
• Positive displacement and entirely closed casing of the bucket ensures the zero loss of the material to be conveyed.
• Very suitable for medium to the higher elevation of the material.

Features:

• The requirement of the layer by layer filling of dry sand in Lost Foam Technology is fulfilled with the sand shower system which provides the Best control over layer by layer filling of dry sand.
• The specially designed perforated plate which is actuated through the pneumatic cylinder allows automatic and manual control over the filling operation.

Features:

Various types of coolers like water-spray type, fluidised bed type, vertical counter blow type are available.

Water-spray type:

• Fastest cooling method available.
• Ideal in case, where additional moisture is desirable.
• No need for any additional airflow.

Fluidised bed type:

• Ideal for fine grain and powder material for cooling.
• Cool air covers most of the grain surface for rapid cooling.
• Available for No-Bake and Lost Foam Process.
• Fluidization is done with a controlled amount of airflow help to remove dust and fines from the sand.
• Provision of a temperature sensing system for output sand.

Vertical counter blow type:

• Gives counterflow to the vertically falling sand (or any grainy material).
• Consumes less power and airflow compared to Fluidised bed type sand cooler.
• Ideal for good availability of height.

Features:

• Direct vibration type knock-out action results in less moving parts and thus less maintenance (unlike indirect type with induced vibration).
• Adjustable counter-weights in vibrating motor for fine-tuning of frequency and amplitude of the deck of Knock-Out according to the requirement.

Features:

• Unlike other traditional sievers with a circular cross-section, Polygonal siever gives the benefit of tossing of the inlet material which gives some benefit in breaking lumps
• Easily removable Stainless Steel wire mess frame for maintenance purpose and long life.

Features:

• Conveys Sand with the help of compressed air.
• Ideal for the plant having compressed air available.
• High flow rates achieved.
• Fully automatic option available.

Features:

• Direct type vibration through vibrating motor for compaction of the mixture.
• Adjustable counterweights for tuning of vibration parameters.
• Rollers mounted on the frame for easy mobility of mould box.
• Air bellow actuated frame for the uplifting of mould box during compaction for rigid gripping on the mould box.
• On frame Control panel for easy operation and control of compaction.

Features:

• The very robust design allows a long life of a machine.
• Easily removable steel grids for maintenance.
• Feeds sand equally through the area of outlet though the principle of vibrating feeder. Thus acting as Knock-Out cum Vibro-feeder.
• Adjustable counter-weights in Vibrating Motor for exact tuning of frequency and amplitude permitting partial control over the vibration.
• Optional Hood with PVC strip curtain provided for Dust Collecting and ergonomy.

Features:

• Safeguards machines such as Belt conveyor, Polygonal Siever, Sand Coolers to remove ferrous particles and purify the end product.
• This Over band Magnetic Separators is used for automatic removal of ferrous contamination.
• Permanent magnet ensures the perfect separation and less power consumption, unlike electro-magnets.

Features:

Water-spray type:

• Fastest cooling method available.
• Ideal in case, where additional moisture is desirable.
• No need for any additional airflow.

Fluidised bed type:

• Ideal for fine grain and powder material for cooling.
• Air of the cooling machine covers most of the grain surface for rapid cooling.
• Available for No-Bake and Lost Foam Process.
• Fluidization is done with a controlled amount of airflow help to remove dust and fines from the sand.
• Provision of a temperature sensing system for output sand.

Vertical counter blow type:

• Gives counterflow to the vertically falling sand (or any grainy material).
• Consumes less power and airflow compared to Fluidised bed type sand cooler.
• Ideal for good availability of height.

Features:

• Provides freedom from the harassment of manual mould handling.
• Ideal for an arrangement of top and bottom part of the mould box.
• Option for fully automatic operation is available.

Features:

• C-type designs for a 90-degree ejection, ideal as a space-saving solution.
• Extensive sizes and configurations for integration into existing workflows.
• Hydraulic-driven for smooth and precise rotation and encoder positioning.
• Variable Width Clamping– Dual opposing hydraulic cylinders fitted with clamping jaws matching the batten board configuration of your patterns are used to clamp the pattern.
• Fully Automatic Operation– The automated upgrade performs the task with a pre-programmed rolling and stripping cycle designed to eliminate a full-time operator.
• Draw-Side Belt Conveyor– This option is employed when the use of a bottom board is not desired. Super-duty belting is used for long life, and ease of replacement is foremost in design.
• Control panel independent and interfaced with PLC.

Features:

• Equally distributed feeding due to vibrating action.
• Adjustable counter-weights in vibrating motor for fine-tuning of frequency and amplitude of the Bed of Vibro-feeder according to the requirement.
• Liners of stainless steel are provided (to prevent corrosion from sand) for the long life of the Bed of the Vibro-feeder.
• uniquely designed Rubber shock absorbers (Rosta make) ensures the absorption of vibration and protects the base frame and ground from Vibration, reduces noise level.

Features:

• Available for both CO2 & No-Bake Process.
• No special skills required to operate
• Access remote for quick recipe change.
• Ensures Uniform Production Quality with minimum
• and easy Calibration.
• Zero sand retention program when stop.
• Tungsten carbide wear-resistant welded blades.
• Corrosion and wear resistance hi chrome
• plating on the inner wall.
• Three standard recipes stored in the program, also modifiable recipes as per customer requirement.
• Easily replaceable blade.
• Mixer opens in two half for cleaning.
• Leakage free magnet coupled pump for the catalyst.
• Directly set above your core shooter.