KURTZ Foundry Machines KURTZ France S.A.R.L. / ERSA France ...

From Foundryman For FoundrymenGravity and Low-Pressure Casting Machines as well as Complete Solutions by Kurtz

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urtz

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Production plants/subsidiariesLocal agentsOther presence

TECHNOLOGIES & SERVICES FOR METALS • ELECTRONICS • PLASTICS

KURTZ Foundry Machines

KURTZ GmbH, KreuzwertheimTel. +49 (0) 93 42 / 8 07-3 15 [email protected]

KURTZ Trimming Technology

KURTZ GmbH, KreuzwertheimTel. +49 (0) 93 42 / 8 07-3 15 [email protected] • www.kurtz-metals.com

KURTZ Machining

KURTZ GmbH, KreuzwertheimTel. +49 (0) 93 42 / 8 07-0 [email protected] • www.kurtz-metals.com

Kurtz Holding GmbH & Co. Beteiligungs KGKreuzwertheim, [email protected]

MBW Metallbearbeitung Wertheim GmbHWertheim, [email protected]

ERSA GmbHWertheim, [email protected]

KURTZ North America Inc.Plymouth, [email protected]

KURTZ Far East Ltd. / ERSA Asia Pacific Hong [email protected]

KURTZ Shanghai Ltd. / ERSA ShanghaiShanghai, [email protected]

KURTZ Zhuhai Manufacturing Ltd Zhuhai, China

KURTZ South East Asia Priv. [email protected]

k•mcSeoul, [email protected]

KURTZ France S.A.R.L. / ERSA FranceTalant, [email protected]

KURTZ Italia S.R.L.Travedona Monate, [email protected]

KURTZ OstMoscow, Russia

KURTZ Systems Africa (Pty) Ltd.KwaZulu-Natal, South [email protected]

KURTZ Foundry Products

Aluminium Foundry, Wiebelbach Aluminium castings of up to 100 kg Aluminium sand castings of up to 1 t

Iron Foundry, Hasloch Grey/nodular cast-iron parts of up to 5 t

Tel. +49 (0) 93 42 / 8 05-0 [email protected] • www.kurtz-metals.com

KURTZ Sheet Metal Technology

MBW Metallbearbeitung Wertheim GmbH, Wertheim and BaiersdorfTel. +49 (0) 93 42 / 96 36-0 [email protected] www.feinblechtechnologie.de

www.kurtz-metals.com

The World is Kurtz –Present in 135 countries

KURTZ GmbHWerk WiebelbachFrankenstr. 2D-97892 KreuzwertheimTel. +49 (0) 93 42 / 8 07-0Fax +49 (0) 93 42 / 8 07-3 [email protected]

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Vision & Mission

Mould Types Alloys ApplicATions services

Dies

Ceramic moulds

Sand moulds

Plaster moulds

Rapid Prototyping

Jobbing foundries

Serial production

Aluminium

Magnesium

Aluminium bronze

Technological advice

Process development

Start-up of moulds

Process optimization

General contractor

Our competitive lead in technology optimizes quality, costs and delivery service in our customers‘ production process.

Our Vision

Our Mission We produce and deliver installations, machines, moulds and com-ponents and render services for the foundry industry.

It is our main goal to optimize our customers‘ production processes.

Our worldwide network guarantees local service to our partners on a long-term basis.

Our core focus is to business areas where we can prove to be “Best in Class” as compared to third parties.

As a corporate group with a tradition dating back to 1779, we feel especially committed to our guiding principles and to long-term corporate goals.

As a division of a family business, we place as much emphasis on an appropriate increase of our own capital and its interest, as we do on long-term development and the safeguarding of jobs. Therefore, we pay special attention that all business divisions achieve above-average longterm profitability.

Low-pressure casting technology & machinesProduct range

This calculation pays off!

Process development by KURTZ

+ Engineering / planning / process

+ Low-pressure casting machines a

. technology

+ Gravity/tilt. gravity casting machines a. technology

+ Automation / handling / finishing

+ Trimming presses and technol

ogy

= Your all around worry-free packet

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LoW-Pressure casting tecHnoLogY LoW-Pressure casting tecHnoLogY

Low-pressure aluminium casting

in open moulds

Visualization and control of the pressure curve

Low-pressure casting machines from KURTZ are designed to meet highest quality demands.

In low-pressure casting, the furnace is pressurized whereby the molten aluminum is brought into the casting die through the riser tube. The die is fi lled by slowly climbing, controlled, and above all, constant pressure. The laminar fi lling process avoids the formation of oxidation, the onset of cold currents and the danger of air inclusions.

The freezing proceeds then from the furthest point of the mould to sprue. During freezing, the furnace pressure is maintained and thus ensures feeding of the castings. Due to casting techniques and the directed use of the die cooling, the ideal of a vectored freezing is reached.

With the feeder box KURTZ offers a previously unknown fl exibility in casting and feeding of parts by means of the low-pressure casting process - independent from the part contour and without additional heat supply. As the number of gating systems and feeders is not limited, several smaller gatings can be positioned in different spots at the casting in order to further reduce cycle times. Further proven option is the use of several riser tubes.

Controlled mould fillingPressure control - hear t and soul of KURTZ systems

Low-pressure casting control with proportional valve technology

Casting with pre-pressure saves time and avoids turbulences

Up to 20 pressure steps possible

HvO remote control for teaching and pre-pressure defi nition, determination of melt level

Indication of set & actual pressure / furnace pressure

Storing of recipes & machine parameters

Control accuracy ±1 mbar

Manual teach-in of the pressure curve

in the riser tube

Low-pressure for metal dies Low-pressure for sand packages

movable clamping plate

dies

casting table

connection

pressure medium

riser tube

electrical resistance furnace

clamping down system

open or closed sand mould

integrated gating system

machine plate with upper end of feeding system

riser tube

electrical resistance furnace

A further advantage of low-pressure casting lies in the reduction of returns. This is impressively demonstrated in the example of a compressor housing. With low-pressure casting, one can count on considerably lower costs for cleaning, rework, and re-melting of returns. Besides, as a rule the output is increased, because

the process is better reproducible and less dependent on external infl uences. No matter whether a classical, rather rotationally symmetric part, or components that require a more complex gating system, is cast: KURTZ always offers the fi tting solution for low-pressure casting.

Comparison of the gravity and low-pressure casting process:

Reduction of returns:

before: part weight: 21.3 kg, output: 54 %

after: part weight 12.2 kg, output: 92 %

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The best quality at the best priceLow-pressure machines of the technology leader

Best Price segMent standard casting MacHines

Ideal solutions for jobbing foundriesHighly flexible universal low-pressure casting machines

for aluminium and magnesium die casting

KURTZ has gained an excellent reputation to supply universal low-pressure die casting machines for jobbing foundries. Their requirements are best fulfi lled by the machine types TC and SC. The crucible type furnace provides best fl exibility to react to different alloys. A further advantage is the compact design for installation even in smaller foundry shops with limited height. Nevertheless the machines are known for their fl exibility. They can be operated using everything from central gating systems to feeder boxes providing the foundryman with a vast range of opportunities. Mould fi lling via temperature control, continuous horizontal and vertical core pull adjustment and, above all, easy storage and upload of casting recipes incl. machine and process data are true machine highlights that pay off!

KURTZ AL 13-13 TC low-pressure

casting machine – highly flexible

and thus especially suitable for

jobbing foundries

Latest achievement is a new low-pressure casting machine in the best-price segment of the market designed for the high-volume production of standardized products such as wheels. The machine is fully equipped and ready to be offered at an affordable price level. Best price segment is far away from anything cheap. Customers will receive the well-known KURTZ quality standard. The KURTZ pressure control system as the key of the process is the most accurate in the market. Furthermore the KURTZ AL 14-10 SR stands out by easy handling and user friendliness. Standardized components provide for shortest delivery periods as well as rapid machine installation and start-up.

KURTZ AL 14-10 SR – starter model with a high

quality standard at an affordable price level

Aluminium wheels – still T H E classical part for the low-pressure casting process

Carrier – alloy GK-AlSi10Mg / 23 kg /

100 % x-ray inspection

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standard casting MacHines STANDARD CASTING MACHINES

Flange

GK-AlSi7Mg / 4.7 kg

Housing

GK-AlSi7Mg dv / 0.29 kg

Contact housing outside

GK-AlSi7Mg / 20.2 kg

Sliding valve housing

AlSi7Mg(0.3)T6 / 4.5 kg

Housing M30

GK-AlSi7Mg / 19 kg

KURTZ foundry machines are well-known for their innovative designs. The 4-pillar design along with the parallel guiding system guarantees an exact closing of the mould. For the operation of the lateral mould segments, KURTZ offers a range of core pulls. For an automated casting cycle, the machine contains mechanical or hydraulical ejectors and an integrated removing device. The furnace is evenly docked on the die by lifting spindle. The design of the docking system allows a fl exible application of various riser tubes and feeder box designs.

A process-optimized die cooling does not only guaran-tee controlled freezing, but also a higher productivity due to shorter cycle times. Due to the use of high-qual-ity parts, the cooling steps can be set in a reliable and reproducible manner. The operating personnel are con-stantly informed of the current process parameters by a monitor. At the same time, the cycle-related data are collected and saved for a subsequent quality analysis.

All KURTZ foundry machines have user-friendly opera-tion, handling and control as well as the possibility to store and activate casting recipes. The modular design of the foundry machines along with many accessories and peripheral systems provides for a high degree of automation, maximal reproducibility and integrated quality management. The design of the optimal low-pressure casting machine depends on customers‘ requirements. We offer low-pressure casting technology under the motto: „Low Pressure - High Quality“

Low Pressure - High QualityKURTZ technology for furnace exchange systems

Particularly in the sector of low-pressure casting, KURTZ solutions enjoy an excellent reputation because low-pressure casting machines from KURTZ are de-signed to meet the highest quality demands. Basically, two different designs are available: Machines with a stationary closing unit or with a movable holding furnace - the so-called S-versions - increase accessibility for maintenance work and allow for utilization of exchange-able furnace systems by means of crane, fork lift truck, furnace shuttle, etc. The S-versions can be equipped with multiple refractory or crucible furnace sizes.

The second version, machines with tiltable closing unit and built-in crucible furnace -

the so called TC-versions - are especially suited for small foundries with frequent alloy changes.

Low-pressure aluminium

casting machine – high flexibility

equipment with crucible

exchange furnace. Application

field: “jobbing foundries“

Engine housing

with radiator ribs

Media block cooling

- water / air

- air cooling

- fog cooling

- control via time

- control via temperature

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sand casting MacHinessand casting MacHines

Gearbox housing Gearbox housing

Oil tank (MSR) made of magnesium

Challenging sand castingFrom rapid prototyping to serial casting

KURTZ aluminium low-

pressure casting machine

for core packages

Magnesium housing

There are several good reasons for the application of KURTZ sand casting machines. Therefore, KURTZ low-pressure die casting technology is also used in well-known foundries such as in the highest categories of international racing. Several teams already count on the advantages of controlled mould fi lling and produce their prototypes and racing engines on KURTZ machines.

The automobile industry is certainly not the only sector which is interested in KURTZ low-pressure die casting technology with precise pressure control. Further applica-tions are in the aerospace industry or in short anywhere where every gram counts in order to keep the mass of moving parts to a minimum. In this context, magnesium casting becomes more and more interesting as well.

By far, aluminium is not the only metal cast on KURTZ low-pressure casting machines. This casting technology also has a huge potential - from aluminium bronze for ship building to magnesium for lightweight constructions in general.

KURTZ aluminium low-

pressure casting machine

for investment castings

In general, KURTZ sand casting machines offer a wide fi eld of application: from chemically bonded sand moulds, constructions with green sand moulds to plaster moulds for special parts with high demands on precise details. Investment casting in ceramic moulds even allows fi ne structures of 1 mm wall thickness.

Diverse moulds - different parts. The product range includes everything from small parts with only a few kilograms of weight to complete housings of 260 kg casting weight, from high-tech prototype single-part to large-scale production.

V8 motor block with bottom

12 1312

Low-pressure casting not only for powerful racers Customized solutions

custoM-Made

Both coreless constructions (open deck design) are cast as well as designs in closed deck, where the handling of the water-jacket core places an additional requirement on the process. The machines are equipped with core pulls corresponding to the casting part, whereby the precise guiding of the dampers is a special construction detail. KURTZ low-pressure casting cells are being employed more and more, especially in the automotive supply sector. Almost every engine in the premium sector of the car industry is cast with KURTZ systems.

The expression “every shot must hit the bull’s eye” goes above all for the fi eld of rapid-protoyping of parts for the automobile industry. Here the keys to success are dependable quality and deadline dependability. These LP sand casting systems do not by far look as spectacular as the large systems, but they have got what it takes. The exact correspondence of the rise of the molten metal level with the pre-programmed pressure curve is the most important criterion here. Deviations and vibrations inevitably lead to rejects. The KURTZ control system sets the standards with respect to precision and process safety.

6 cylinder in-line crank case for diesel engine,

alloy AlSi7 for BMW

“The standard is not enough by itself and we can’t just be cheap either.” Real solutions to customers’ requirements are needed. Thanks to the broad make-up of the KURTZ team and the synergies with the in-house aluminium foundry, KURTZ has been able to acquire an excellent reputation in customer-specifi c special solutions. This is corroborated by outstanding customer references, such as BMW, KS ATAG, Honsel, Grunewald or Mahle. The application spectrum of KURTZ low-pressure casting machines reaches from rapid prototyping to serial casting up to special solutions; for example, the casting of cylinder crank cases.

The highest metal quality is achieved through a furnace exchange system. The trend continues to low-pressure casting of castings in sand core packages and sand moulds. Here, above all, the high metal quality and the low-turbulence fi lling of the mould are ideally utilized. The process is suited for the small number of pieces of the pilot lot up to an automatable mass production. In this context the metal foundries Steinrücken, Becker CCC and Grunewald can be named as competent partners of KURTZ.

Generally, the target products for aluminium low-pressure casting lie in safety relevant parts, whose highest quality demands are of top priority. These can, for example, be chassis or motor parts. Moreover, the low-pressure casting process is also predestined for pressure tight components with the highest load demands in vacuum technology and hydraulic technology.

That’s how KURTZ offers countless individual engineering solutions for low-pressure casting, always faithful to the motto: Everything from one mould!

custoM-Made

Aluminium low-pressure casting machine

for the production of V6 to V12 cylinder crank

cases (left) or of 4 to 6 cylinder in-line crank

cases for KS ATAG (below)

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coMPLete soLutions coMPLete soLutions

Complete KURTZ casting line

with refractory furnaces

Low-pressure aluminium casting machine

with handling robot, peripheral equipment and

materials handling technology

Apart from the expertise as manufacturer of casting machines, KURTZ has also been supplying casting parts for about 150 years. The business segment “Kurtz METALS“ includes an iron as well as an aluminium foundry. This leads to unique synergy effects due to a continuous and intensive exchange of know-how. The latest developments in casting technology are directly transferred into the design of KURTZ casting machines.

As a “third party manufacturer”, KURTZ offers in its foundries the complete process from casting develop-ment and design including advice on material selection to casting and the fi nished part. The KURTZ casting machine division also acts as a supplier of a complete system. Therefore, the customer can expect complete solutions from one source: from casting and process development through the steps mould making, installation of the machine on site, mould start-up and training to pilot-production run or the responsibility as a general contractor.

No matter which requirements you have in the fi eld of casting – KURTZ has the right solution. Contact us, we will realise all your demands according to our vision.

Complete solutions -From Foundryman For FoundrymenUnique synergies and all- inclusive services

KURTZ complete solutions

General contractor

Toolmaking

First sampling of moulds

Process optimization

Automated casting cells

Low-pressure casting machines

Robot controlled cells for the deburring and fettling of iron and aluminium castings

Decoring machines3-D detail of a complete KURTZ casting cell / line with

handling systems and shuttle-type exchange furnace

KURTZ AL 13-13 FSC low-pressure casting machine with

optimum process control and shuttle-type exchange furnace

For the serial production of a wide and demanding product

range KURTZ offers complete casting lines. They can, for

example, be equipped with furnace exchange systems

assuring an extremely quick furnace exchange, highest melt

qualities and minimum scrap after the furnace exchange.

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eXcerPt FroM our reFerencescooPerations & coMPLete soLutions

Gravity casting plants,handling & moreComplete casting cells

KURTZ provides tiltable gravity and gravity casting ma-chines which are available as single machine or turn-key complete solutions / complete casting cells. The fl exible machine concept is easily adaptable to different custom-er requirements: low cost or high tech versions, maxi-mum fl exibility for frequent product changes or individual customized solutions.

Apart from automated casting processes the focus is on core and part handling. Additional features and peripherals are realized subject to requirement. Servo-hydraulic, i. e. control-led, casting machines are used for tiltable gravity casting with robot. Free programming of both robot and casting machine is absolutely quick and easy; robot and casting machine must run synchronously to obtain high-quality castings.

What is valid for the low-pressure casting fi eld is of course also valid for KURTZ gravity and tiltable gravity casting machines: complete solutions from one source meeting your requirements!

Ejectors with hydraulic coupling

Cooling systems:water-, air- ormixed cooling

Machine, tilted by 90°, servo-hydraulic tilting motion, tilting angle of up to 110° possible

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HistorY

since 1779

KurtZ grouP & ManageMent sYsteM

The Kurtz Group

process model

The Kurtz Group

The Kurtz Group is comprised of several companies from different business sectors. The strategic management is positioned in Kurtz Holding GmbH & Co., while the operational responsibility lies with the individual segments.

Our integrated management system directs all the processes and assures that the demanding quality requirements of our customers are satisfi ed. We regard the protection and preservation of nature as a great responsibility. We continually investigate possibilities for making our own contribution to environmental protection.

A matrix organization with the business segments PLASTICS, METALS, ELECTRONICS and SERVICES ensures the greatest possible degree of fl exibility and customer proximity.

Business segments and products

Foundry products

Machining

Low-Pressure casting Machines

sheet Metal technology

shape Moulding Machines

Pre-expanders

Blockmoulds

sheet Processing

stencil Printers

soldering systems

soldering tools

inspection systems

rework systems

Know-How transfer

used Machines and assembly service

total Maintenance Quality service

innovation support

engineering

Worldwide more than 1,100 people

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Founded as iron hammer works in 1779 in Hasloch, Spessart, the Kurtz Group has developed into aninternationally operating conglomerate. Today, we are technological or world market leaders in many fi elds.

The corporate group is in the ownership of the sixth generation of the family.

The management can fall back on an advisory board consisting of excellent industry personalities.

Our control centre:

The headquarters of the Kurtz Group are in Wiebelbach –

not far from the iron hammer works in Hasloch.

Where it all began:

The historical iron hammer works in Hasloch, Spessart,

remains in operation today as an industrial memorial.

Fine Traditions And A Bright Future

KURTZ Foundry Machines KURTZ France S.A.R.L. / ERSA France ...

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Transcript of KURTZ Foundry Machines KURTZ France S.A.R.L. / ERSA France ...