Molding

Automatic DISAMATIC lines can produce castings with minimum tolerances which cannot be reached with the use of other casting methods. This fact is supported by the following two factors:
1. Simplicity and selectivity of DISAMATIC principle excludes exchange of molds. The molds always remain in the same plane which ensures maintaining each plane in its original state to the very moment when castings are removed from their molds. 
2. DISAMATIC machines are designed with such high precision which can be reached only with the help of machining. Also the machines are very reliable. All movable parts and joints are precisely controlled and have a high degree of reliability. They are made of special wear-resistant materials. 

DISA 131-Z is a sand shooting molding machine which makes pressurised separable vertical flaskless sand molds. 

Main components of the mold production mechanism include the following: 
- Molding chamber with fixed bottom plate, top plate and side plates.
- Movable pattern plates.
- Sand hopper.
- Sand shooting mechanisms and
- Hydraulic system which applies pressure required for pressing and transporting molds.

DISA 131-Z line for flaskless molds works according to the following principle whereby all operations are performed continuously and simultaneously while the line works in a flow mode.

Data about patern plates are input into control system with the help of keyboard which is located on operator's panel. With reference to available information the control system automatically sets operational parameters of mechanical, electrical, pneumatic and hydraulic units in the molding system. 

A ready mix which is conditioned at the sand plant is further supplied to the molding machine where flaskless molds are made by means of pressing.  Working cycle of the molding machine is divided into 6 operations. Control LEDs on the operator's panel indicate operations which are performed by the machine at a certain moment which gives an operator a possibility of following the working cycle and makes the machine maintenance easy. 

These operations are:
1. Fill molding chamber with sand (sand shooting)
2. Press molds
3. Remove front pattern
4. The the mold and transfer a string of molds
5. Remove rear pattern 
6. Close molding chamber.

Filling molding chamber with sand 
A hopper for sand shooting is located above the molding chamber and connected with it through an ejection channel. Optimum channel dimensions allow making a ready mix threshold above the channel. The molding sand is supplied to the chamber with the help of compressed air. Lining in the sand shooting hopper is made of stainless steel which prevents sand from sticking to the hopper walls. 
Main components of the sand shooting mechanism are air receiver and a controlled sand shooting valve. Air pressure in the air receiver is adjustable. The air is supplied from the central air line through a special inlet. 
The DISAMATIC working cycle starts when the sand hopper is full and the sand gate is closed. Patterns are in the chamber at a selected depth. After that the sand shooting valve opens for a specified period of time which can be controlled, while the air pressure is preset. This makes sand to be blown from the hopper through the ejection channel to the molding chamber (Operation 1) which results in a homogeneous preliminary mold pressing. 
It is important to control speed of filling the molding chamber with sand, because turbulance can lead to an excessive wear in pattern plates while in molds it can make soft spots.

Removal of patterns from molds and transfer of molds

Manipulations with molds are minimized so as not to damage them. A patented DISAMATIC principle is a reliable system which pushes and transfers molds. After pressing of molds a front pattern plate slowly retracts. A strong structure of the counterpressure unit provides complete parallelism of molds during their pushing which is the first and foremost condition for maintaining mold shapes.
After the front pattern is retracted from a mold the pattern quickly moves away from the front part of the chamber and turns to a horizontal position which allows pushing molds from the chamber (operation 3). 
After that the pattern plate pushes the mold out of the chamber. Prior to joining a string of molds its speed reduces noticeably which ensures a flexible approach of the mold to the string. When a preset pressure between molds is reached the whole string of molds gets accelerated (Operation 4). The АМС (Automatic Mold Conveyor) provides pressure which is required to move a string of molds forward. During this movement pressure from the molding machine piston is kept at a preset level which contributes to maintaining constant pressure between molds. 
The pressure is set with due regard to reaching an optimum axial load onto the molds, i.e. with regard to a minimum pressure load which is required to avoid any gaps between molds due to hydrostatic pressure. When making molds with horizontal parting the above pressure is applied with the help of a special weight. The balanced force ensures optimum use of pattern plates and completely excludes deformation of molds. 
When a stroke force is set with regard to pattern plates, sand and type of metal, synchronized systems of electricl control, molding machine and АМС automatically adjust transfer force depending on friction and load from a string of molds. The string of molds moves forward to a distance which is precisely equal to one mold thickness. When a string of molds stops a rear pattern plate slowly retracts to its initial position in the chamber (Operation 5).

Closing the molding chamber
Finally the front pattern plate gets into a vertical position and closes entrance to the chamber. The working cycle is completed (Operation 6).

Sand cores are made of sand on the Core Machine and are supplied to the molding machine operator. A core setter allows putting sand cores into molds with the purpose of getting interior cavities (surfaces) in castings. An operator puts cores into the core setter whereby the core is moved to the АМС where it gets firmly connected with a previous mold. Without the core setter it is impossible to perform this operation and get (for example) a ventilated brake disc.

The АМС is connected with the molding machine, controlled by it and works continuously with it. Here we pour iron into ready flaskless molds. On the AMC castings cool down to solidification temperature. 
Afterwards molds with castings are transferred to SBC (Synchronized Belt Conveyor) which is also an integral part of the molding machine, gets controlled by it and serves to be its continuation. The SBC moves synchonously with the molding machine operation. 

On the SBC molds with castings get further cooled down to shake out temperature.