Modulated machine design
for core production with inorganic binders
Laempe & Mössner GmbH
Inorganic binders
Main Advantages
- Emission and odor free for humanity and environment,
- Compliance with future environmental laws,
- Reduction of casting failures caused by core gas,
- Condensate deposit on the mould drop or rather decrease significantly,
thereby increase in productivity and cost reduction in the maintenance,
- Decoring ability due to adjustable water soluability,
- Reduction of disposal costs of the used sand,
- Cost savings in the field of exhaust technique and scrubbers
- Higher uptimes of core boxes based on lower cleaning time
- Etc.
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Inorganic binder
Organic binders burn
Inorganic binders are inert
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Inorganic binder
Organic binders burn, condensates
contaminates the mold
With inorganic binders
the mold is clean
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Basic Facts
Characteristics of inorganic binders
 Hardening physically and chemically
 Mostly physical instead of chemical reaction
Characteristics in machine engineering
 Opportunity to heat toolings
 Opportunity for hot air flushing
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Green-Line-Concept
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Comparison Coldbox/HotBox/Inorganic
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Challenges and Solutions
Challenge:
Avoid dry and hardening of core sand in the shooting nozzles due to dry and hot
ambient atmosphere.
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Solutions:
Cooling of the shoot plate and the nozzles as know from hotbox system or shell core.
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Problem:
In difference to hotbox systems wherein hardening starts by temperature only,
inorganic system will dry out at the nozzles‘ tip even when cooling the nozzle.
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Solutions:
Moisturing of the ambient area around these shooting nozzles by water spray.
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Problem:
Water droplets will condensate at the cool nozzles, water droplets wash away binder
skin from the sand grains and cause defects in the core surface and body.
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Solutions:
Water not to be sprayed in as droplets but as cold vapor. The evaporation of the
water will be done by ultra sonic generator (system patended by Laempe).
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Technical Solutions
Ultra sonic vaporing of shooting nozzles
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Technical Solutions
Ultra sonic vaporing of shooting nozzles
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Challenges and Solutions
Challenge:
Avoid dry and hardening of core sand in the sand hopper above the machine and
in the shooting unit after the shot.
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Solutions:
Moisturing of the air above the sand level by water spray and covering of the
hopper top.
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Problem:
Water droplets will condensate at the cool nozzles, water droplets wash away
binder skin from the sand grains and cause defects in the core surface and body.
↓
Solutions:
Water not to be sprayed in as droplets but as cold vapor. The evaporation of the
water will be done by ultra sonic generator (system patended by Laempe).
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Solution
Kernschießmaschinentechnik
Ultra sonic vaporing of shooting unit
Solution
Kernschießmaschinentechnik
Ultra sonic vaporing of shooting unit
Solution
Kernschießmaschinentechnik
Ultra sonic vaporing of shooting unit
Challenges and Solutions
Kernschießmaschinentechnik
Challenge:
Due to the lower floability of certain binders and depending to the design of the shoot plate, sand channels may be
formed in the shooting system.
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Solutions:
Using of a „bridge breaker“(system patended by Laempe).
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Side effect:
Using the bridge breaker will also deliver informations about the sand level in the shooting unit and so optimize
sand dosing – even under such conditions where conventional optical systems will not work.
Forming of „sand channels“
Challenges and Solutions
Kernschießmaschinentechnik
Challenge:
(Most) Inorganic binders require warm or hot coreboxes. Coreboxes need to be heated up to 200°C (392°F)
Heating methods
Advantages
Disadvantages
electrical heating by conventional
resistance heaters
•
known technology from hotbox
technology
easy to operate
accurate temperature control
easy tool designing, especially if
separate heater plates are used
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good heat transfer
known technology from high
pressure casting process
easy to operate
accurate temperature control
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exellent heat transfer
Reduced piping system required
compared to oil heating
High energy density
accurate temperature control
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Thermo transfer oil
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Steam
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Only middle-rate heat transfer
heater cardrigdes reduce
freedom of tool design;
efficiency of the heat transfer is
depending to tool accuracy
for big toolings energy transfer
requires big cables
tool design unusual for
coreboxes due to liquid
channels
complex piping system required
mostly unknown technology to
pattern makers and operators
hot steam under high pressure
Challenges and Solutions
Kernschießmaschinentechnik
Test equipment:
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Specially adapted coreshooter type LBB10
10 l shooting volume
Equipped to operated all known binder processes
Mixer directly installed above sand shutter
Ultra sonic moisturing system for shooting system
and shoot plate
Challenges and Solutions
Kernschießmaschinentechnik
Heating equipment:
Oil temperature unit make ROBOMAT and steam generator make CERTUSS.
Both systems with heating capacity of 30 kW.
Challenges and Solutions
Kernschießmaschinentechnik
Comparisson of piping system:
Oil pipes with supply line and back line for each circuit.
Steam system with supply line for each circuit
and common back line.
Special Solutions
Not only for inorganic bonded cores…
Challenge:
Identification of castings in relation to core production data, like shift, binder or sand
batch, etc. even after batch-independent core storage.
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Solutions:
Marking the cores by an ink printer directly after production and engraving a code by
laser into the sand core.
Special Solutions
Kernbearbeitung – Lasern/Bedrucken
Contact
Thank you for your attention!
Let‘s work together to keep our world for the next generations.
Laempe & Mössner GmbH
Tel: + 49 (0) 7622 / 680 0
Fax: +49 (0) 7622 / 680 391
Email: info@laempe.com
Laempe & Mössner GmbH
Schopfheim
Grienmatt 32
D - 79650 Schopfheim
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