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Sinto America Inc.’s FBMX series flaskless machine performs a two-stage mold compaction process. Stage 1 is a pre-compaction via top- or under-aeration sand filling; Stage 2 is performed by secondary compaction involving double-sided squeezing.

Aerated Sand Filling is the Next Step in Horizontal Molding

Feb. 2, 2024
A new design involving a two-stage molding operation adds excellent mold quality to the existing advantages of flaskless molding.

Flaskless molding technology allows metalcasters to achieve flexibility in mold size and shape, with the reliability of automation, while optimizing throughput. Now, Sinto America has introduced the FBMX series of horizontal molding machine that also offers the advantage of excellent mold quality because it adopts the developer’s aeration sand filling technology.

These are compact and dependable molding systems, offering flask sizes from 17x21 to 32x32 inches.

The FBMX series molding machine performs a two-stage mold compaction: Stage 1 is a pre-compaction via top- or under-aeration sand filling; Stage 2 is performed by secondary compaction involving double-sided squeezing.

Cope and drag sand filling are achieved by maintaining the horizontal orientation of the flasks. This orientation stability continues when sand is introduced as a top-fill or under-filling process. Using top- and under-filling contributes to high dimensional accuracy in finished castings, and the orientation of the top and under fill will lend to better success filling the deeper profile patterns.

Top aeration sand filling promotes uniform sand filling density in the flask. An aeration sand tank is provided for low-pressure sand fluidization. Inflowing molding sand is delivered by a nozzle system to the mold cavity, and aeration and pressure time are adjustable.

Under aeration sand filling likewise achieves uniform sand filling density, with an aeration sand tank provided for low-pressure sand fluidization, and inflowing sand delivered by a nozzle. Aeration pressure and timing are adjustable.

FBMX series molding machines offer a “balance squeeze control” in the hydraulic flow control circuit. Automatic adjustment of the cope and drag squeeze pressures will avoid unbalanced loading on the match plate. This balanced load will help the operators achieve a high degree of pattern draw accuracy due to the continuous stability of the matchplate during squeezing. As a result, there is no distortion of the matchplates – even matchplates made from plywood can be used in operation of the machine.

The FBMX series machines will continuously monitor the compressibility of each mold, and a feedback control automatically records the height of each mold after each cycle. Then, the sand feed volume is automatically calculated, and the sand requirements is adjusted for proper compensation. Reduced sand consumption and compensation of compactability variations will result in less scrap and higher casting quality.

Among the FMBX system options offered to foundries are automatic core setting, pattern plate preheating, condition monitoring, process visualization and analysis, pattern-change assistance, pattern-inspection area light curtains

These capabilities can be enhanced by linking the FMBX molding system to the Sinto Smart Foundry analytics toolbox, which seamlessly collects data on all the production systems in a foundry equipment. SSF is a single source for compiling analytical information about all types of equipment for presentation on dashboards and in reports.

In this Smart Foundry framework, the FBMX is the next step in the development of horizontal molding.

Andy Schelke is the Vice President Foundry for Sinto America Inc.

About the Author

Andy Schelke | Vice President - Foundry

Andy Schelke is the vice president – Foundry, with Sinto America Inc. Contact him at [email protected], or visit www.sintoamerica.com