Requirements
To choose the right casting technology we need the following information:
- Quantity of parts
- Material specification
- Necessary tests
- CNC machining information
- Desired delivery schedule
Mold design
- CATIA, ProE, Siemens NX, GeoMagic, 3Devolution, Creo, Magics
- mold design depending on customers requirements, quantity and used Rapid Prototyping techniques
- raw part design, adding machining allowance, design of the prepared feeding and gating system
- define the split lines for mold segmentation and necessary cores, cores fitted with core prints for mold assembly
- mold segments and cores are fitted with interlocks
- finally the assembly of the generated mold is checked
- optimal mixture of different mold production techniques is provided by special software developed by ACTech which taking into consideration the best price/performance ratio
Simulation
- requested by customer
- ANSYS, PROCast
- FEM (Finite-Elemente-Analyse) analysis simultaneously with design process
- casting simulations
- mold filling and solidification simulation
- prediction of internal stress, deformation and possible casting defects
- optimization of casting technology
- determining the pouring setup
Mold manufacturing | Sand casting
- using 3D-CAD data for manufacturing and quality control:
- Laser sintering of Croning® material
- additive manufacturing
- cores, almost unlimited geometric freedom
- 3D Printing
- additive manufacturing
- 3D furan resin printing for complex cores and mold segments
- 3D phenolic resin printing for high strength cores
- DMM® - Direct mold milling
- mold segments up to 2,400 mm
- CNC milled pattern
- Laser sintering of Croning® material
- compare mold segments and cores with the 3D-CAD data using optical measurement
- monitor the mold assembly process with tactile and optical measuring technique for tight tolerances
- data mining for later non- destructive tests and machining setup
Mold manufacturing | Investment casting
- using 3D-CAD data for manufacturing and quality control
- controlled cooling and storage of wax positives
- optical measurement for quality checks
- technologies:
- primary model production by laser sintering of polystyrene
- plaster mold technology
- using wax or polystyrene models
- plaster cuvette production by melting the original models
- ceramic mold technology
- using wax or polystyrene models
- ceramic mold production by decanting, sanding and melting of the original models
- patented drying technology
- casting of steel and iron is possible
Foundry
- aluminum, grey iron, ductile iron, compacted graphite iron, alloyed and high alloyed steel, customer alloys
- patented Cooling method for mechanical properties comparable to series part characteristics
- vacuum supported pouring technology for thin wall thicknesses
- 850kg melting capacity for aluminum
- 500 kg melting capacity for iron and steel alloys
- core removal with shock wave technology
- heat treatment according to requirements
Raw part
- finish
- optical measurement vs CAD data set
- wide range of construction and production welding methods
- Tungsten inert gas welding
- Al DC Negative Pole manual welding
- Manual metal arc welding
- Cast iron hot welding similar and dissimilar
- Gas metal arc welding
- Laser welding
- complete testing of the customer requirements to the raw part
- Tightness testing, crack detection, Fluoroscopy
- X-ray inspection (160kV device, radioscopy)
- Visual inspection and endoscopy from 2 mm diameter
- Ultrasonic thickness gauge
- surface treatment requested by customer
Finished part
- CAM programming with Tebis and TopSolid
- VERICUT machining simulation
- Alignment with live optical measurement raw part data vs 3D-CAD-data
- complete external machining setup
- Tool presetter with online data transfer
- Shuttle table systems
- CNC machining
- 5-axis simultaneous technology
- mill/turn and turn/mill- technology
- up to 1,500mm table size available
- In-Process measurement technology
- Quality testing with 3D coordinate measurement, contour and roughness measurement
- Tightness testing, Finish and assembly
Projektmanagement
- Lead Project Manager
- Responsible for all internal and external communication
- Coordinates work of the foundry project managers and the machining project manager
- Provides technical customer service for key accounts or special projects only
- Foundry Project Manager
- Specialized in casting techniques, applications and materials
- Responsible for raw part production details
- Machining Project Manager
- Specialized in applications only, independent of markets or technology
- Responsible for manufacturing details of machining
- Live-Tracking for customers
