Automatic green molding for iron castings
Automatic green casting is one of the most established and reliable technologies for the industrial production of iron castings for small and medium runs.
At the Fonderia Quaglia & Colombo, this process is managed by a dedicated department, designed to ensure production continuity, dimensional precision, and consistent quality of the finished products. Thanks to a highly automated system and constant monitoring of the characteristics of the casting sand, the foundry is able to promptly respond to the needs of industrial sectors requiring reliability, repeatability, and long-term stability.
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Automatic green forming department
The Fonderia Quaglia & Colombo automated green molding department was developed to support structured production while maintaining high operational flexibility.
The facility uses a shock wave molding machine with four casting lines, a solution that allows for efficient management of production cycles and optimization of production times.
The system is equipped with automatic plate changeover, a key feature for reducing machine downtime and ensuring seamless transitions between production runs. The plates used measure 860 x 580 x 300 300 mm, allowing for a wide range of casting geometries and configurations.
Technical characteristics of the system
The automatic green forming plant is designed to ensure consistent and controlled performance throughout all production phases. Production capacity reaches up to 45 flasks/hour, making the department suitable for mass production with consistent quality standards.
The system is completed by a horizontal-axis mixer, a key element in maintaining the green sand's properties. This allows for uniform rigidity of the molds, ensuring dimensional stability, which is essential for the precision of the pieces produced and for reducing defects.
Small and medium series production
Automatic green molding is primarily intended for the production of small and medium-sized castings, weighing up to 100 kilograms. This production configuration effectively meets the needs of components intended for various industrial sectors, where a balanced combination of production volumes, casting quality, and cost control is required.
The repeatability of the process and the stability of the operating conditions allow for consistent results even over extended production cycles, reducing the need for corrective interventions and improving the overall efficiency of the department.
Quality control and production continuity
To ensure higher quality, the green automatic forming process is integrated into a carefully monitored production flow.
Controlling raw materials, managing the sand and binder mixture, and verifying operating conditions allow us to maintain high standards throughout the entire supply chain.
Process automation reduces operating variables and contributes to greater dimensional consistency of the castings, an essential element for subsequent processing and for the integration of components within complex mechanical systems.
Experience and technological updating
The Fonderia Quaglia & Colombo in Legnano, in the province of Milan, has been operating in the cast iron sector since the 1940. Throughout its history, the company has consistently invested in plant renovations and technological upgrades, integrating modern solutions such as automated green casting into a production vision focused on quality and reliability.
This process represents just one of the various technologies present in the foundry, but it constitutes a point of reference for productions that require precision, continuity and process control.
FAQ
What is green automatic forming?
It is a forming process that uses green sand and automated systems to create molds for casting iron in a continuous and controlled manner.
What types of production are suitable for automatic green forming?
It is particularly suitable for small and medium series castings, with repetitive geometries and weights up to 100 kg.
What advantages does it offer over manual processes?
It guarantees greater repeatability, dimensional consistency, reduction of operational variables and production continuity.
What role does the earth mixer have?
The horizontal-axis mixer keeps the characteristics of the molding sand constant, improving the rigidity of the shapes and the quality of the casting.
Is green automatic molding suitable for continuous industrial production?
Yes, thanks to its capacity of up to 45 brackets/hour and high level of automation, it is ideal for structured and continuous production cycles.
