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Process Optimization Premachining and Decoring: New Fill Test Center

Editor: Nicole Kareta

Reproducible test results in close-to-production conditions create the very best circumstances for developing high-performance machine and system concepts. At the state-of-the-art Test Center on the Gurten site, Fill Machine Engineering offers its customers optimum options for joint component tests and trials.

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True to the motto “Test the best”, Fill offers its customers an opportunity to evaluate, optimize, and verify processes in the field of premachining and decoring.
True to the motto “Test the best”, Fill offers its customers an opportunity to evaluate, optimize, and verify processes in the field of premachining and decoring.
(Source: Oliver Hallwirth / raumpixel)

The new Test Center is equipped with the most innovative technologies and developments from Fill’s Casting Technology and Profile Technology Competence Centers. On the TWISTMASTER 400, components up to 400 kg (clamping fixture including casting) are decored, whereby no turning on the component’s own axis is required. For challenging geometries, the SWINGMASTER models (maximum payload 315 or 500 kg) provide ideal conditions for an optimally decored final product. “Hard-as-steel machining power meets cybernetic intelligence in our new Test Center. In these real-world tests, our customers can gain a first-hand impression of the performance and precision of our machines and systems,” explains Thomas Rathner, Head of the Casting Technology Competence Center at Fill.

Tests on Customer Premises

Fill also offers the option of tests on customer premises with its mobile hammering station. The robust CORECRACKER preliminary decoring unit uses hydraulic hammers to break the sand core of the casting before the actual sand removal process.

Concentrated Innovative Strength Creates Added Value

The decoring center is equipped with all the machines used by Fill’s casting technology customers around the world. Decoring is typically a two-stage process. In the first step, the core is broken by hitting the component with targeted hammer blows. In the second step, the broken core fragments are removed from the casting using a high-energy vibration system. For step one, both pneumatic and hydraulic hammers are available for tests on customer components. Depending on component size, the subsequent decoring process is performed with the SWINGMASTER 315, SWINGMASTER 500, or TWISTMASTER 400. For greater insight and better documentation, the process is recorded with four video cameras. Fill CYBERNETICS records the testing and analyses the data in real time. Two large screens are attached outside the cabin to allow the tests to be followed live. Once test operation is complete, a detailed report on the series of tests, including photos and videos, forms the basis for a joint final analysis. In this state-of-the-art Test Center, Fill offers its customers a unique opportunity to collaborate on implementing a reliable, stable, highly economical casting production process, tailored to the customer’s individual requirements.

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