ARCONTEC - diagonal sidecore system ASS

Video clip: ASS 4-sidecore-system	Video clip: ASS 8-sidecore-system	Video clip: ASS 4-sidecore-system

New development of a low pressure casting mould
ARCONTEC – diagonal sidecore system ASS

The objective of the new development is first of all to optimise the casting process; furthermore to improve the blank quality and to achieve a productivity increase.

The advantages towards of current mould systems appear as follows:

1. Tool preparation and assembly of the mould

1.1. Tool preparation The time for dismantling and recomposing the mould for the purpose of heating up, blasting and coating, is substantially lower due to the simplicity of the construction assemblies.

2. Casting process

The pure saving of time while casting results by the absence of a seperate opening/ closing of the side cores.

3. Quality improvement of the blank

By an even closing of the mould we achieve a much lower wear and tear at the sealing surfaces. The necessity of a follow-up treatment is substantially reduced.

Every side core is separately adjustable, while the mould is mounted on the casting machine.

4. Servicing of the mould

   By leaving out the ejectors a considerable disturbing factor is cancelled.
   The servicing of the mould (cleaning, coating, etc.) is facilitated by an easy access to all parts.

5. Casting machine/ Servicing

   By leaving out the lateral guiding hydraulic elements there is considerably less need for servicing, production means and operation.

6. Productivity increase

With this new development an increase in production is made possible by setting the stage for casting two identical moulds at the same time on one casting machine.

7. This new develoment is protected by a patent. All rights reserved by ARCONTEC Argirov GmbH.

Advantages and findings during quantity production
of aluminium wheels [Feedback]

• Temperature measurements with a special videocamera: The lower core has a lower temperature (10-25° C cooler) as with horizontal side core casting moulds.
  Advantage - better surface of the blank. Especially good quality for front-copied wheels.

• Noise measurements (in decibel) during a complete casting cycle:
  Advantage - 50% less noise exposure due to the compact construction in comparison to horizontal side core casting or other diagonal side core casting systems.

• Direct influencing/reduction of possible burr formation by means of adjustment of every single side core ( more axis adjustment ).

• Easy and quick cleaning of the mould on the casting machine due to the easy accessibility of all mould components.

• Direct and quick exchange of the side cores upon the machine without dismantling of the mould. By putting on a panel on the corners of the opened mould the side cores are dismountable with each two screws.

• No distortion of the blank while mould releasing, because blank releasing is carried out in contrast to all existing mould systems in reverse order.
  Advantage - higher rotation accuracy is achieved; lower allowance laying for the mechanical conditioning; quicker and easier mechanical conditioning, because less aluminium has to be cut by chip removal; considerable aluminium-economization; no scrap because of drafting.

• Due to none existing ejectors the construction/configuration of the deairing-boring is unrestrictedly defineable.

• Good temperature distribution of the mould.
  Advantage - improve mechanical properties of the blank, higher tensile strength in the rim and rib-adaptation.

• The inside contour of the mould has got only deairing nozzles and is closed in itself.

• Nearly maintenance-free mould. Moved elements close and open the mould with lesser effort respectively friction freely of compulsion.
  Advantage - Very robust construction of the complete mould; nearly no abrasion in moved elements.

• Open construction method of mould halves.
  Advantage - residues of aluminium, dirt, dust are blown out without remains from the mould; no scrap due to concluded contaminants.

• More favorable thermionics than with customary moulds.
  Advantage - the loss through waste reduced while casting on the mould (up to quantity production) more than 50%.
  With customary moulds the loss through waste amounts to approx. 13-16 pieces, with the new mould system „ASS “ approx. 5-8 pieces.

• All plates are grinded level-in parallel, so that more accuracy of the whole mould construction is achieved.
  Advantage - lower friction therefore also less wear, an easier servicing and care is guaranteed.

• The ASS-mould is marked by compactness (low whole dimensions) and simplicity of all components:
  Advantage - considerably lower total weight of the mould in comparison to other diagonal- sidecore- moulds. Quicker warming up is guaranteed. Easy storage in a shelve system (low weight and dimensions).

• In the quantity production a loss through waste is achieved less than 1%. Numbers of pieces (X-rayed wheels) from approx. 340 pieces per day are reached.

• The mould is applicable universally on all current casting machines:
  Advantage - it requires no changes or adaptations of the casting machine as well as in the machine control.

• The cooling air is conducted and controlled outwardly:
  Advantage - cooling system can form closed circulation. As a cooling medium water or a water oil mixture can be used, also in combination with air pressure, for the handling of the ASS-mould.

• The high closing pressure of the machine affects straight the closing pressure of the mould:
  Advantage - optimum density of the mould; no burr formation in separation planes, the mould can be used with variable (raised) filling pressure.

• The ejector mechanism of the ASS-mould does not intervene in the inside of the mould:
  Advantage - no ejectors which wear out the upper core, can break or stuck; no aluminium discharging in the ejector drillings; no deformation of the blank as well as no marks in the blank.

• The duration of a casting cycle during the quantity production is shorter approx. 20 seconds than with horizontal side- core- moulds:
  Advantage - higher productivity.

• No hydraulic side- core- cylinders are required for ASS-moulds:
  Advantage - no down-times caused by defective cylinders; simplistic hydraulic system.

• The ASS-mould can be used with grey iron or with steel side-cores.