AMINE COLD BOX CORE MAKING

-THE NEED OF THE HOUR

B. B. Lohiya
Director
Compax Industrial Systems Pvt. Ltd.
Pune, India.

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Customer is our
Asset
  all else
Liability !!

Compax - An ISO 9001 Company !!

HIGH VOLUMES
STRINGENT QUALITY DEMANDS
SHORTER DELIVERY PERIOD
LOWER COST

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 TAKE CARE
OF
YOUR
CORESHOP !

IT WILL TAKE
CARE OF
YOUR
QUALITY
CASTINGS !
Compax - An ISO 9001 Company !!
 PRODUCTIVITY FACTORS
RATE OF PRODUCTION
QUALITY ASSURANCE
COST ECONOMICS
ENERGY CONSERVATION
HUMAN SKILL AND FATIGUE
ENVIRONMENT

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 Basic Principle
 

The Amine Cold Box Process is based on the use

of a Sand Mix with Phenolic Resin and a
Polyisocynate, which cure instantaneously at
ambient temperature in the presence of a
gaseous Amine Catalyst. The reaction is
irreversible and produces a strong Polyurethane
bond.

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 COLD BOX BINDER
CHEMICAL REACTION
 

 LIQUID + LIQUID SOLID

PART I PART II BINDER

 
PHENOLIC + POLY AMINE POLY

RESIN ISOCYANTE CATALYST URETHANE

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 FEATURES OF AMINE COLD BOX
PROCESS
 
    AMBIENT TEMPERATURE:
 
     No heating of core box is required, so use of Wooden,Resin
or Aluminum core box is possible.
     Less casting development time.
     Saving in energy cost.
     No sagging / distortion of core since no heating is involved
     Since no need of heating of core box, tag of production time
can be eliminated.
     Since core box and cores are at ambient temperature
handling is easy.No fatigue to operator

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   INSTANTENEOUS :
     Core takes shape of core box as it is
     No Dimension distortion
     Excellent Productivity
     Cores can be taken for assembly within few hours
 
   HIGH STRENGIH :
      High core strengths can be achieved hence excellent
quality castings can be produced
 
   IRREVERSIBLE :
      Excellent Dimensional stability

Compax - An ISO 9001 Company !!

Compax - An ISO 9001 Company !!
Compax - An ISO 9001 Company !!
Compax - An ISO 9001 Company !!
ADVANTAGES OF CORE MAKING COLD BOX PROCESS
OVER SHELL PROCESS

Description Amine Core Box Process Shell Process

Productivity 300 to 350 shots shift 100-150 shots shift

2 to 3 times more then shell

Energy Conservation Since no heating of tooling is Heating of tooling is

required 30 to 40 % less then required, thus cost of
shell. energy is more.

Versatility Cost Iron, shell non ferrous Same

metals can be cast.

Surface Finish Excellent core casting can be Excellent

eliminated in most of the
applications

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Dimensional accuracy Since the bond is formed Chances of dimensional
instantaneously, the sand mix distortion due to heat.
assumes the dimensions of the core
box.

Dimensional stability Since the reaction is irreversible, Since heating of tooling is

excellent dimensional stability required chances, of
dimensional distortion
after cooling of the
core/mould

Collapsibility Easy shakeout, good break down Knock out properties are
and knock out properties. Takes not as good as in the case
50% less time than shell. of Cold Box.

Gas Evolution Least as compared to all core Highest as compared to

making processes with organic all core making processes
binders i.e. 12 to 15 cc/gm. Hence i.e. 25 to 28 cc/gm
better insurance against blow holes.

Hot strength Similar as in shell. Good resistance

to erosion
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Human fatigue Reduced human fatigue & skill since Since heating of tooling is
production and handling is at ambient required more human
conditions fatigue due to high
temperature ambience.

Tooling development Less cost of tooling by almost 30% as High cost of tooling since
compared to shell since resin, only metallic tooling has to
wooden or non-metallic tooling can be be necessarily used.
used.

Tooling development Substantially less 2 to 3 weeks More as compared to cold

time box 6 to 8 weeks

Flexibility to use Variety of core production in a shift is
tooling possible since process is cold, core
box can be replaced within 10 to 15
minutes. Thus cores can be produced
as and when required.
Since tooling is hot operator
has to wait for 2 to 3 hours
to allow it to cool down
before tooling change

Cost of core per kg of Rs. 3.60 to 4.00 per kg of Sand Rs. 6 to 8 per kg of Sand
Sand (Cost of sand
binders and energy)

Compax - An ISO 9001 Company !!

ADVANTAGES OF AMINE COLD BOX
PROCESS
30 % cheaper than shell process
No heating of core box is required so saving in energy cost since no
heating is required. Use of Wooden, Aluminum, Epoxy,
Polyurethane core box is possible.
Both features or nonferrous casting can be produced in this
process.
Excellent surface finish (No need of casting is most of the case).
Excellent knockout properties.
Low gas evolution compared to any other organic binders.
Less casting rejection.
Excellent hot strengths since good tensile strength can be achieved.
Good Dimensional stability & core strength hence machining
allowance can be reduced ultimately of costing can be reduced.
Since process is carried out at ambient temperature good working
condition helps to enhance productivity.

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WORK CLUTURE FOR COLD BOX CORE SHOP

1.    No Smoking
2.   Keep the premises completely dry. Moisture is dangerous to the strength of the
core Dirt, Clay Oil droplets & moisture are enemies of cold box.
3.    Take care of your cold box sand. Use the sand mix within 20 minutes of
preparation
4.    Take care of the core box and it will take care of your care requirement. Clean
the core boxes frequently.
5.    Operate equipment only if you are authorised to do so.Know it well before you
operate it.
6.    Clean the Sand hopper, Sand cylinder. Sand magazine, the core boxes and
the machine at the beginning and end of each shift and also whenever you wish to
take a break for more than 20minutes.
7.     Keep all doors of the machine closed and cover lids during operation of the
equipment.
8.     Use hand gloves as required for handling of consumables.Store the cores in a
very dry atmosphere.
9.     Keep your core making equipment always clean and tidy. It will give you
longer service.

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 KEY FACTORS IN THE APPLICATION

A successful utilization of Amine Cold Box Process will require :

   Sand, free of moisture (less than %1) and clay

(less than 2 %)
     Use of dry air (Dew point better than - 20)
     Proper venting of the core box
     Dimensional accuracy of the core box.
     Highly polished interior surfaces of the core box.
     Properly matched and sealed parting surfaces
     High clamping force
     Properly selected shooting / gassing holes and shooting / gassing areas
     Smooth ejection mechanisms.
     Properly balanced elements of the installation (such as mixer, core production
centers,core boxes etc.)
     Compatible work culture

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 AMINE COLD BOX PROCESS REQUIRMENTS
Consumable Typical Usage
a) Sand As Required
 Dry, Washed And Graded Silica Sand (Mangalore sand
) AFS 50 – 55
 Moisture Content Less than 0.1 %
 Clay content less than 0.2 – 0.3 %
 Low ADV Value (Around 5)
Uniform Grain Structure
b) Chemicals
  Resin (Part 1) 0.8% - 1%
  Isocynate (part 2 ) 0.8% - 1%
  Tri Ethyl Amine 0.15%

c ) Carrier medium Air

d) Air 4000 – 6000 CFT per ton of

stand

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e) Electricity 4 to 6.5 kW up to 10 Kg shooter

f) Coating Not required in most of cases

g) Cycle / hour 40 – 100 (Depending on the Tooling &

Core configuration

Important :- 
The consumption of raw material as well as the production
rate is dependant on type of Core configuration , quality of
sand , Type of tooling , Shooting and gassing Techniques
Sealing Of joints etc.

Compax - An ISO 9001 Company !!

Compax - An ISO 9001 Company !!
 HIGH CLAY CONTENT
 
HIGHER BINDER REQUIREMENT
 

  HIGHER COST HIGHER GAS EVOLUTION

 

 
REDUCED FLOWABILITY
 
 
POOR CORE COMPACTION
& POOR STRENGTH
 

HIGHER BLOW PRESSURE REQUIRED

  

SEGREGATION OF SAND FLUIDISATION OF SAND

 

POOR SURFACE FINISH REDUCED STRENGTH

 

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Types of Toolings

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Compax - An ISO 9001 Company !!
Shooting & Gassing locations

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Compax - An ISO 9001 Company !!
 Sealing

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 TRENDS IN COREMAKING EQUIPMENT

FAST
FLEXIBLE
PROGRAMMABLE
INCREASED LEVEL OF AUTOMATION,
INBUILT SAFETY
QUICK TOOLING CHANGE
COMPATIABLE HANDLING SYSTEMS

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Compax - An ISO 9001 Company !!
Compax - An ISO 9001 Company !!
Compax - An ISO 9001 Company !!
Compax - An ISO 9001 Company !!
Sand Distribution System

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Compax - An ISO 9001 Company !!
  
 
 

Compax - An ISO 9001 Company !!

 Higher output/Unit Time
Compax
Higher Output/Unit labour
Cold
Higher Output/Unit Investment
Box
Higher Output/Unit Energy
Production
Lower Binder Consumption

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PNEUMATIC FLOW DAIGRAM

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 HYDRAULIC FLOW DIAGRAM
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                    

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