UNIVERSITY OF CRAIOVA

Faculty of Mechanics

Specialization

Project
for
Innovative Technologies in Automobiles
Manufacturing
Coordinating teacher:

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University of Craiova Faculty of Mechanics

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 Disamatic casting

DISAMATIC is an automatic production line used for fast manufacturing of sand molds
for sand casting. This process is commonly used to mass manufacture of metal castings for the
automotive and machine industry.

History
In 1957, Vagn Aage Jeppesen - professor at the Danish Technical University claimed a
patent for a device producing flaskless molds of sand mixtures with vertical parting lines for
casting metal parts. In 1960, Danish company Dansk Industri Syndikat A/S (DISA) acquired the
patent and started working on its implementation.
In 1962, a half scale prototype of a sand molding machine with flaskless and vertically parted
molds under the name of DISAMATIC was ready to be disclosed. During the International
Foundry Trade Fair (GIFA) in 1962 in Düsseldorf the scale model was demonstrated on DISA's
stand. This resulted in sales of two first DISAMATICs to European foundries. The first
automatic DISAMATIC molding lines could produce up to 240 complete sand molds per hour.

Process
DISAMATIC consists of a molding machine and mold transporting conveyor. A molding
sand mixture, usually green sand or bentonite, is blown into a rectangular steel chamber using
compressed air. The molding sand is then squeezed against two patterns, which are on the two
ends of the chamber. After squeezing, one of the chamber plates swings open and the opposite
plate pushes the finished mold onto a conveyor. Finally, any cores are automatically set into the
mold cavity while the next mold is being prepared. The cycle repeats until a chain of finished
molds butt up to each other on the conveyor.
The molds are then filled with molten metal and placed on a cooling conveyor, which
moves at the same pace as the fabrication conveyor. At the end of the conveyor the solidified
castings are separated from the molds and processed further, while the sand is directed to the
sand preparation plant for reconditioning and reuse in the next cycles of the DISAMATIC
molding process.
The basic setup is shown below.

Step 1. Sand is blown into the Molding Chamber from above.

Step 2. The Ram advances, pushing the Ram Pattern. This compresses the sand in the Molding
Chamber to form mold impressions.

The compression creates opposite halves of consecutive molds placed in the mold string.
Castings cannot be formed using a single mold, but when a new mold is placed in the mold
string; its leading edge meets the trailing edge of the previous mold to create a completed mold
cavity.

Step 3. The Swing Pattern moves back and up to allow the mold to exit the Molding Chamber
Step 4. The Ram extends, pushing the new mold into the existing mold string.

Step 5. The Ram and Swing patterns return to their original position to begin the process again.
Step 6. Sand is blown into the Molding Chamber for the next mold. A little further down the
mold string, iron is poured into the top of a formed mold via the pouring sprue left by the pattern
impressions.

Efficiency
The DISA New Generation machines are designed perfectly for the cost effective production of
large quality castings due to an extremely rigid machine design with an unmatched high speed.
This gives the highest output compared to the investment while securing optimum reliability and
uptime.
When producing castings on the DISA 240-280 machines, flasks are a thing of the past and
variable mould thickness capability means lower sand consumption and constant metal-to-sand
ratio. The result is the fastest and most competitive production of near net shape castings.
Advantages
The DISAMATIC sand molding process has several advantages comparing to other
molding processes. It does not use flasks, which avoids a need of their transporting, storing and
maintaining. It is fully automatic and requires only one monitoring operator, which reduces labor
costs. Molding sand consumption can be minimized due to variable mold thickness that can be
adjusted to the necessary minimum.
A modern DISAMATIC molding line can mold at the rate of 550 sand molds per hour
(one complete mold in 6.5 seconds). Maximum mis-match of two halves of the castings does not
exceed 0.1 mm (0.0039 in). Total uptime exceeds 98%. Possible mold sizes range from 400 x
500 to 850 x 1200 millimeters. A DISAMATIC line can be completed with automatic casting
and sand cooling drums, robotized devices for extracting castings from the molds and automatic
casting cleaning and abrasive blasting machines placed inline. In such automatic production lines
there is no need of any human manual labor until the castings are completely finished and ready
for dispatch.

13 good reasons for choosing the DISA New Generation

1. Fastest moulding machine on the market with up to 450 uncored moulds an hour
2. Superior uptime with fewer moving parts, more rigid design and reduced maintenance
and parts usage
3. Minimal machine-related mismatch for less fettling, lower production costs, increased
efficiency and higher earnings
4. Comprehensive real-time computer integrated manufacturing (CIM) monitoring and
reporting for optimum production process efficiency and quality
5. Low manpower requirements
6. Automatic Pattern Change Unit for fast pattern change in 60 seconds (75 seconds for
DISA 280)
7. Ventilated brake disc (grey iron) Boiler (grey iron) Transmission housing (grey iron)
8. Fast and easy installation
9. Double-sided mold squeeze operation and adaptive mould thickness for consistent and
dense moulds
10. Safe, clean and quiet for a good working environment
11. Low power consumption
12. User-friendly operator panel with text and graphics for easy operation and quick
troubleshooting
13. Low sand consumption with consistent sand-metal ratio.
References
1. http://www.metal-technologies.com/docs/default-
source/education/disamaticmolding.pdf?sfvrsn=8511cd02_2
2. https://en.wikipedia.org/wiki/DISAMATIC
3. http://www.foundry-planet.com/fileadmin/redakteur/pdf-dateien/English_-
The_DISAMATIC_R__for_everyone_FactSheet.pdf
4. http://www.morikawa-inc.com/technical-iinformation/casting-products/green-sand-
manufacturing-process