Products

• Automobile castings
• Hydraulics
• Brake segments
• Castings for sewerage systems
• Stove and grates castings

Technologies

Material of the castings

Gray cast iron: EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300 

Production capacity

Production capcity: 20 000 tons/year

Production series: 1 - 500 000 pcs/year

Casting weight: 0,5 - 50 kg

Casting size

Automatic frameless moulding line DISA 240 

Moud dimensions [mm]: 

775 x 600 x 150 - 500 

Maximum casting weight: 50 kg

Automatic frameless moulding line HFM 40 

Half-mould dimensions [mm]: 

720 x 560 x 150- 500

Maximum casting weight: 40 kg

Machine moulding 

Maximun frame size [mm]: 

900 x 800 x 300

Maximum casting weight: 100 kg

Preparation of the production

Zlievaren Trnava, Ltd., provides complete technical preparation of production of castings. In order to design the castings and pattern equipments, the CAD system “Pro-engineer” is used. For simulation of pouring, flow of melted metal in th emould, coolinf of the casting and elimination of inside defects we use simulation system MAGMA .Zlievaren Trnava, Ltd., has its own toolshop. The patterns and core boxes are depending on the expected production series manufactured from metal, plastic, wood or combination of the  mentioned materials.

Production of castings

The metal is being melted by turns in two cold-air cupola furnances with diameter of 900mm. It is homogenised and modified in electric forehearth with the cpacity of 9 tons. The moulds are produced from bentonite mix.

Moulding

Is provided by:

• two automatic moulding lines

            -  horizontal dividing plane - HFM 40

                                                        (max. dimension of the mould 720x560x250/250)

            -  vertical dividing plane - DISA 240B

                                                        (max. dimension of the mould 775x600x150/150)

• semiautomatic moulding machines with horizontal dividing plane with variant calibre from 465x365x90/90 up to max. 900x 800x 300/300

Casting

HFM40 using the casting device George Fisher with capacity 2,5 tons.

DISA 240B using the casting device Otto Junker with capacity 8,8 tons.

Hand casting from the ladle is also possible on the moulding lines.

Production of cores

COLD BOX method

1. ROPER H 12 machine with gas generator LUBER LW 520
2. ROPER H 2 machine with gas generator MF A 35
3. AVS 8 machine with gas generator MF A 35 Formservis

HOT BOX method

1. AVS 16 device
2. AVS 6-2x device
   

CO2 method

Oil cores

The majority of the core production is provided by COLD BOX systems, in case of extra strained cores HOT BOX system is used.

Finishing operations

For finishing of the castings there is an adequate number of drum abrasive cleaning machines  together with  transversal machine with the cpacity of 20 tons per shift. Finishing is being done on doudle wheel grinders. To grind complicated castings hand grinding is used. Based on the customer requirements the casting surface treatment can be carried out  by painting (dipping, spraying) with different hues and types of colour. The castings are packaged in accordance with customer requirements, preferably on euro-palettes.

Quality kontrol

Zlievaren Trnava, Ltd., owns the ISO 9001/2009 quality management certificate.  To ensure constant quality of production the following mechanical, chemical and physical testing is performed: 

• temperature of meta
• chemical composition
• hardness measurement
• strength measurement
• metallographic analysis
• dimension check
• moulding mix quality check