1. QUALITY CONTROL

An independent supervisory department is controlling, monitoring and qualifying the processes and the final production.
The in house Laboratory is controlling the chemical composition of the metal and incoming materials, as the mechanical properties of the castings. See List of machinery and apparatuses used.

2. PATTERNS / MODELS

Own Pattern shop that makes patterns without limitations in sizes, complexity.
Large Patterns for small series on hand moulding are made of hard wood and plywood.
Smaller patterns for large series and Automatic Molding line are made of Aluminium or special, wear resistant resin.

3. TECHNOLOGY FOR PRODUCTION OF CAST

HAND MOULDING

In the workshop “Large castings” castings are produced in furan, only hardening molding mixture by hand or vibration gasket. Molding mixture was prepared mixers and system for regeneration of sand on the English company “Omega” cores used in this workshop are made of furan only hardening molding mixture or coated sand (“Hot-box” technology)

AUTOMATIC MOULDING LINES.

The Foundry has two (2) such lines made in Germany by “KÜNKEL WAGNER”.
Both lines are located in the mill for small and medium sized/weight castings.
The casting/moulding is based on Green sand Technology
Automatic molding line. Sizes of the flasks: 1000мм х 800мм х 350мм / 350мм.
Capacity/output – 35 flask sets / hour. Recommended weight of the castings from 6 to 220 kg.
Semi-Automatic moulding Line: Sizes of the flasks: 1700mm х 1350mm х 350mm / 500mm / 650mm .
Productivity/output : eight (8) sets of flasks /hour. Recommended weight of the castings: 220 ÷ 900 kg (480 Lbs. to 1980 Lbs.).
The foundry cores used in this mill are made by „Cold-box“ technology (mixture of phenol resin hardened by blowing with СО2) , or „Hot-box“ technology

CONTINUOUS CAST GREY IRON BARS of Grade GJL 250.

Rounds with diameters 30 mm to 250
Squares with sizes fro 40 x 40 mm to 120 x 120 mm.
Rectangles with sizes 50×60 mm up to 110x 120 mm.
Lengths of the bars 3100 mm.

4. PREPAIRING OF THE LIQUID METAL

The melting and preparation is made in four (4) low frequency electro- induction furnaces.
The types of Iron used is:
Grey Iron acc. to EN 1561/1997 and NODULAR (DUCTILE) Iron acc. to EN 1563/1997.
 

Grey Iron EN 1561/1997 NODULAR (DUCTILE) Iron EN 1563/1997
EN-GJL-100 EN-GJS- 350-22-LT
EN-GJL-150 EN-GJS- 400-18-LT
EN-GJL-200 EN-GJS- 450-10
EN-GJL-250 EN-GJS- 500-7
EN-GJL-300 EN-GJS- 600-3

5. CLEANING / FETTLING / DEBURRING OF THE CASTINGS

The cleaning is made by hand using pneumatic and electric instruments.
The removal of the sand mixture, after the Shaker is made by shot blasting machines.
Available are three (3) shot blasting chambers:
For castings up to 1 ton is used a conveyer chamber “KONRAD RUMPF”.
For larger and heavier castings are used stationary shot blasters “GOSTOL”. One is with sizes 2,30 x 2,40 x 4,0 meter and the other is with a rotating table diam. = 3,50 meter.

6. MACHINING OF THE CASTINGS

The Foundry offers rough machining of the castings. For this purpose on an area of
10 300 square meters (m2) are located the following machines :

LIST OF THE AVAILABLE MACHINERIES IN THE MACHINING WORKSHOP

1. Planing machines (bohrverg) – LARGE sized – 2 Units.
Sizes to be treated (max Height x Breadth x Length)
H – 2500 mm; B – 4000mm ; L – 2000 mm. Max Weight of casting – 20 ton.
Electric Power of the engine – 45 kW.
2. Planing machine – MIDLE sized – 1 Units.
Sizes to be treated (max Height x Breadth x Length)
H – 2500 mm; B – 4000mm ; L – 2000 mm. Max Weight of casting – 20 ton.
Electric Power of the engine – 20 kW.
3. Planing machine – SMALL sized – 1 Units.
Sizes to be treated (max Height x Breadth x Length)
H – 1000 mm; B – 1300mm ; L – 1200 mm. Max Weight of casting – 4 ton.
Electric Power of the engine – 5 kW.
4. Planing machine (hobel) with 2 columns /pillars – 1 Units.
Sizes to be treated (max Height x Breadth x Length)
H – 800 mm; B – 1200mm ; L – 4000 mm. Max Weight of casting – 5 ton.
Electric Power of the engine – 40 kW.
5. Planing machine (hobel) with 1 column – 2 Units.
Sizes to be treated (max Height x Breadth x Length)
H – 800 mm; B – 1200mm ; L – 4000 mm. Max Weight of casting – 5 ton.
Electric Power of the engine – 40 kW.
6. Planing machine (hobel) – LARGE sized – 2 Units, model 2872.
Sizes to be treated (max Height x Breadth x Length)
H – 2000 mm ; B – 2800mm ; L – 8000 mm. Max Weight of casting – 20 ton.
Electric Power of the engine – 160 kW.
7. Planing machine (cutter) – 1 Units.
Sizes to be treated (max Height x Breadth x Length)
H – 1300 mm; B – 1300mm ; L – 5000 mm. Max Weight of casting – 10 ton.
Electric Power of the engine – 60 kW.
8. Vertical Lathe – 1 Units.
H – 2000 mm ; Diameter of plan pulley – 2500 mm. Max Weight of casting – 10 ton.
Electric Power of the engine – 20 kW.
9. Vertical Lathe – 1 Units.
H – 800 mm; Diameter of the plan pulley – 1000 mm. Max Weight of casting – 1 ton.
Electric Power of the engine – 20 kW.
10. Milling machine – model 654.
Sizes to be treated (max Height x Breadth x Length)
H – 1000 mm ; B – 1000mm ; L – 1900 mm. Max Weight of casting – 5 ton.
Electric Power of the engine – 7,5 kW.
11. Universal Lathe – model C 13.
L – 3000mm ; Diameter of the plan pulley – 400 mm
El. Power of the engine – 7,5 kW
12. Universal Lathe – model C 11- 3 units.
L – 2000mm ; Diameter of the plan pulley – 250 mm.
El. Power of the engine – 4,5 kW.
13. Radial drilling/bore machine.
R – 2000 mm ; H – 1200 mm.
El. Power of the engine – 3,0 kW.
14. Gear /cogwheel making machine – For Modules 3 to 10.
15. Channel cutting machine
H – 1000 mm. El. Power of the engine – 4,5 kW.
16. Flat grinding machine.
B-600 mm ; L-1200 mm. El. Power of the engine – 4,5 kW
17. Center machine with CNC. B-1000 mm ; L1200 mm. El. power -4,5 kW.

These are just some of the machinery used more often in the
Mechanical treatment & repair work shop with covered area 10 300 m2

7. FINISHING OPERATIONS

HEAT TREATMENT, PRIMER and PAINTING .
The Foundry has two electro – resistance chamber furnaces with sizes 2,40 x 2,60 x 4,20 meters.
The thermal treatment is with Temperatures up to 8000 C, with max weight of the castings -20 ton.
For the Customers the Foundry offers primer and final lack painting of the castings