From Foundryman For FoundrymenGravity and Low-Pressure Casting Machines as well as Complete Solutions by Kurtz
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by K
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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79 F
ound
ation
of t
he ir
on h
amm
er w
orks
in H
asloc
h
1852
Fou
ndat
ion o
f the
iron
foun
dry i
n Ha
sloch
1860
Firs
t mac
hine
build
ing a
ctivit
ies
1896
Fou
ndat
ion o
f “M
gM M
etall
-gies
sere
i-Man
nhei”
1921
Pat
ent r
egist
ratio
n of
the
electr
ical s
older
ing ir
on
1962
new
buil
ding
of th
e fo
undr
y
1968
Pro
ducti
on o
f sold
ering
mac
hines
1971
Pro
ducti
on o
f par
ticle
foam
mac
hines
1982
tak
e-ov
er a
lumini
um fo
undr
y
1983
Pro
ducti
on o
f fou
ndry
mac
hine
s
1984
Fou
ndat
ion o
f Kur
tZ n
orth
am
erica
1985
new
buil
ding
of th
e m
achin
e fa
ctory
1988
Fou
ndat
ion o
f Kur
tZ F
ar e
ast /
Hon
gkon
g
1990
tak
e-ov
er of
bloc
kmou
ld fa
ctory
in a
ltaus
see
1990
Fou
ndat
ion of
Kur
tZ F
ranc
e / K
urtZ
italia
1993
tak
e-ov
er o
f ers
a so
lderin
g te
chno
logy
1996
Fou
ndat
ion o
f MBW
shee
t met
al te
chno
logy
1998
Fou
ndat
ion o
f Kur
tz Ho
lding
as p
aren
t com
pany
2001
imple
men
tatio
n of
saP
r/3
2003
cer
tifi ca
tion
acc.
to d
in is
o 90
01 ff
2003
Fou
ndat
ion o
f Kur
tZ Z
huha
i Man
ufac
turin
g
2006
new
buil
ding
of th
e M
BW sh
eet m
etal
plant
2006
Fou
ndat
ion o
f Kur
tZ o
st in
Mos
cow
2006
HiP
Ham
mer
inno
vatio
n Pr
ogra
mm
e
2007
Fou
ndat
ion o
f “Ku
rtZ
Ferti
gung
stech
nik”
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