Big Step Forward for Green Sand Molding

June 1, 2021
A new version of DISA’s vertical molding platform continues the emphasis on speed, throughput, and finished-product quality, and joins the trend toward large-scale casting production.

The relevance of “oversized” cast parts has become a guiding issue in some segments of metalcasting over recent years – notably in high-pressure diecasting, where lightweight designs of automotive structures has pushed the previous limits of component consolidation and simultaneously in the scale of metalcasting machinery.

But diecasters are not the only ones pushing those limits. DISA, the Norican Group business long noted for its automatic green-sand molding machines, has introduced the DISAMATIC® D5 vertical molding machine. “The digital-ready Disamatic D5 is perfect for ambitious foundries that want a future-proof way to transform big casting production,” according to DISA v.p.-Product Development Nina Rasmussen.

The Disamatic D5 is based on the D3 platform, a vertical molding system introduced in 2015, with an emphasis on high speeds, high yields, and extended uptime. That system offered throughputs of up to 555 uncored molds per hour (or 485 cored molds per hour.)

Now the D5 arrives to underscore those attributes, with faster throughputs, higher yields, and maximum uptime. It replaces the Disamatic 240 and 250 models and is available in three mold sizes up to 650×850 mm and 500 mm thick. The D5 has three speeds of operation, up to 450 uncored molds per hour, and combines premium mold quality with speed, short-run flexibility and minimum maintenance, according to the developers

“We’ve built on the worldwide success of the Disamatic D3,” Rasmussen continued, “evolving the design and adding numerous upgrades that help achieve the very lowest cost-per-casting. The D5 features many smart innovations and powerful automation options that let it handle large pattern plates, cores and filters precisely, quickly, and safely.”

DISA also calls attention to the new machine’s environmental performance. The D5’s energy efficiency and other enhancements cut CO2 emissions and reduce waste while lowering operating costs and increasing yields, thereby improving productivity.

Along with new hydraulic system and control capabilities, the D5 incorporates what DISA describes as “smart innovations, like the new ”moldability” features that let foundries produce a wider range of large, complex castings while maintaining impeccable quality.

These new functions include “Adjustable Squeeze Distribution,” which balances swing plate and pressure-plate squeezing distance to handle difficult castings easily, completely filling deep pockets and promoting optimal surface finish with consistent mold hardness.

Another new function, “Adaptive Pouring Position,” maintains a constant distance between the D5 and the pouring unit so as to minimize pouring-cup movement. Reportedly, this improves casting quality and line speed, while other features like re-squeeze, enhanced sand blow-off, and extra heating in the sand shot system and hopper remove loose or sticking sand to improve surface quality and significantly reduce scrapped castings.

With a standardized Quick Pattern Changer, the Disamatic D5 maintains high speed and flexibility. Options like the Automatic Pattern Changer and Automatic Core Setter enhance the machine’s ability to maintain stable, high-quality production and complete multiple pattern changes per shift.

The NoriGate gateway (a Norican Group standard interface) is pre-installed, so the D5 is supplied as Industry 4.0-ready.

DISA emphasized the new machine is built for rigidity and simplicity, with standardized components that promote easy service, low maintenance costs, and long service life. The operations is described as “user-friendly, quiet, and dust-free,” contributing to a hospitable working environment and making workers’ tasks more attractive with features like an intuitive touchscreen control panel.

Leda Werk, a foundry in Leer, Germany, that manufactures cast-iron stoves, fireplace inserts, and similar products, has installed the Disamatic D5 to support high-volume output of large castings, replacing a DISA 250 – retaining the primary molding dimensions for previous machinery. Reportedly, the new machine fit into the existing line with minimal disruption.

“We have now replaced all our vertical molding machines with the latest D-series Disamatics and have future-proofed our processes,” stated foundry manager Rochus Hiller. ”The investment in new, state-of-the-art equipment has enabled us to reduce our operating and maintenance costs, improve our energy costs, and achieve high machine availability.”

“With the D5, our customers can produce large castings at higher quality and greater speed while cutting their operating costs to the bone. Like all Disamatics, D5 molding lines deliver consistent, repeatable and high quality molds right from the start to give the lowest cost per casting – and that’s exactly what our customers are looking for,” Rasmussen concluded.