From Foundryman For Foundrymen

Kurtz Holding GmbH & Co. Beteiligungs KG
Kreuzwertheim, Germany
[email protected]
www.kurtz.info
MBW Metallbearbeitung Wertheim GmbH
Wertheim, Germany
[email protected]
ERSA GmbH
Wertheim, Germany
[email protected]
KURTZ North America Inc.
Plymouth, USA
[email protected]
137714 - 12/2009 | subject to changes | © 2008 by Kurtz Holding GmbH & Co.
TECHNOLOGIES & SERVICES FOR
METALS • ELECTRONICS • PLASTICS
KURTZ Far East Ltd. / ERSA Asia Pacific
Hong Kong
[email protected]
KURTZ Shanghai Ltd. / ERSA Shanghai
Shanghai, China
[email protected]
The World is Kurtz –
Present in 135 countries
Production plants/subsidiaries
Local agents
Other presence
Kurtz Zhuhai Manufacturing Ltd
Zhuhai, China
KURTZ South East Asia Priv. Ltd.
Singapore
[email protected]
KURTZ Foundry Machines
KURTZ Foundry Products
KURTZ GmbH, Kreuzwertheim
Tel. +49 (0) 93 42 / 8 07-3 15
[email protected]
www.kurtz-metals.com
Aluminium Foundry, Wiebelbach
Aluminium castings of up to 100 kg
Aluminium sand castings of up to 1 t
KURTZ Trimming Technology
KURTZ GmbH, Kreuzwertheim
Tel. +49 (0) 93 42 / 8 07-3 15
[email protected] • www.kurtz-metals.com
KURTZ Machining
KURTZ GmbH, Kreuzwertheim
Tel. +49 (0) 93 42 / 8 07-0
[email protected] • www.kurtz-metals.com
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
k•mc
Seoul, Korea
[email protected]
KURTZ France S.A.R.L. / ERSA France
Talant, France
[email protected]
KURTZ Italia S.R.L.
Travedona Monate, Italy
[email protected]
Kurtz Ost
Moscow, Russia
KURTZ Systems Africa (Pty) Ltd.
KwaZulu-Natal, South Africa
[email protected]
MBW Metallbearbeitung Wertheim GmbH,
Wertheim and Baiersdorf
Tel. +49 (0) 93 42 / 96 36-0
[email protected]
www.feinblechtechnologie.de
Gravity and Low-Pressure Casting Machines
as well as Complete Solutions by Kurtz
KURTZ GmbH
www.kurtz-metals.com
From Foundryman For Foundrymen
Werk Wiebelbach
Frankenstr. 2
D-97892 Kreuzwertheim
Tel. +49 (0) 93 42 / 8 07-0
Fax +49 (0) 93 42 / 8 07-3 19
[email protected]
www.kurtz-metals.com
Vision & Mission
Our Vision
Our Mission
Our competitive lead in technology
optimizes quality, costs and delivery service
in our customers‘ production process.
We produce and deliver installations, machines, moulds and components 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.
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Low-pressure casting technology & machines
Mould Types
Alloys
Product range
ApplicationsServices
Dies
Aluminium
Rapid Prototyping
Technological advice
Ceramic moulds
Magnesium
Jobbing foundries
Process development
Sand moulds
Aluminium bronze
Serial production
Start-up of moulds
Plaster moulds
Process optimization
General contractor
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LoW-Pressure casting tecHnoLogY
LoW-Pressure casting tecHnoLogY
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 %
Controlled mould filling
Pressure control - hear t and soul of KURTZ systems
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 filled by slowly
climbing, controlled, and above all, constant pressure. The
laminar filling process avoids the formation of oxidation,
the onset of cold currents and the danger of air inclusions.
Low-pressure aluminium casting
in open moulds
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
flexibility 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.
Manual teach-in of the pressure curve
in the riser tube
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 lowpressure 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
Low-pressure for metal dies
movable clamping
plate
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 definition,
determination of melt level
dies
casting table
connection
pressure medium
riser tube
the process is better reproducible and less dependent
on external influences. No matter whether a classical,
rather rotationally symmetric part, or components that
require a more complex gating system, is cast: KURTZ
always offers the fitting solution for low-pressure
casting.
Low-pressure for sand packages
clamping down system
open or closed
sand mould
integrated gating
system
machine plate with upper
end of feeding system
riser tube
Indication of set & actual pressure / furnace pressure
Storing of recipes & machine parameters
Visualization and control of the pressure curve
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electrical
resistance furnace
electrical
resistance furnace
Control accuracy ±1 mbar
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standard casting MacHines
Best Price segMent
KURTZ AL 14-10 SR – starter model with a high
quality standard at an affordable price level
Ideal solutions
for jobbing foundries
Highly flexible universal low-pressure casting machines
for aluminium and magnesium die casting
The best quality
at the best price
Low-pressure machines of the technology leader
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 has gained an excellent reputation to supply
universal low-pressure die casting machines for
jobbing foundries. Their requirements are best fulfilled
by the machine types TC and SC. The crucible type
furnace provides best flexibility 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
flexibility. They can be operated using everything from
central gating systems to feeder boxes providing the
foundryman with a vast range of opportunities. Mould
filling 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
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
Low Pressure - High Quality
KURTZ technology for fur nace exchange systems
Engine housing
with radiator ribs
Particularly in the sector of low-pressure casting,
KURTZ solutions enjoy an excellent reputation because
low-pressure casting machines from KURTZ are designed 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 exchangeable 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.
Flange
GK-AlSi7Mg / 4.7 kg
Housing
GK-AlSi7Mg dv / 0.29 kg
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“
Contact housing outside
GK-AlSi7Mg / 20.2 kg
Sliding valve housing
AlSi7Mg(0.3)T6 / 4.5 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 flexible application of various riser tubes and
feeder box designs.
A process-optimized die cooling does not only guarantee controlled freezing, but also a higher productivity
due to shorter cycle times. Due to the use of high-quality parts, the cooling steps can be set in a reliable and
reproducible manner. The operating personnel are constantly 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 operation, 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 lowpressure casting machine depends on customers‘
requirements. We offer low-pressure casting technology
under the motto: „Low Pressure - High Quality“
Media block cooling
- water / air
- air cooling
- fog cooling
- control via time
- control via temperature
Housing M30
GK-AlSi7Mg / 19 kg
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sand casting MacHines
sand casting MacHines
In general, KURTZ sand casting machines offer a wide
field 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 fine
structures of 1 mm wall thickness.
Oil tank (MSR) made of magnesium
V8 motor block with bottom
Magnesium housing
KURTZ aluminium lowpressure casting machine
for investment castings
Challenging sand casting
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.
From rapid prototyping to serial casting
There are several good reasons for the application of
KURTZ sand casting machines. Therefore, KURTZ lowpressure 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 filling 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 applications 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.
Gearbox housing
Gearbox housing
KURTZ aluminium lowpressure casting machine
for core packages
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custoM-Made
custoM-Made
6 cylinder in-line crank case for diesel engine,
alloy AlSi7 for BMW
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 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 filling 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.
The expression “every shot must hit the bull’s eye” goes
above all for the field 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.
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!
Low-pressure casting not
only for powerful racers
Customized solutions
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)
“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-specific 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.
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coMPLete soLutions
coMPLete soLutions
Complete solutions From Foundryman For Foundrymen
Unique synergies and all-inclusive ser vices
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 development and design including advice on material selection
to casting and the finished 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.
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.
No matter which requirements you have in the field of
casting – KURTZ has the right solution. Contact us, we
will realise all your demands according to our vision.
KURTZ complete solutions
General contractor
Toolmaking
First sampling of moulds
Process optimization
Automated casting cells
Low-pressure casting machines
3-D detail of a complete KURTZ casting cell / line with
handling systems and shuttle-type exchange furnace
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KURTZ AL 13-13 FSC low-pressure casting machine with
optimum process control and shuttle-type exchange furnace
Complete KURTZ casting line
with refractory furnaces
Robot controlled cells for the deburring and fettling
of iron and aluminium castings
Decoring machines
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eXcerPt FroM our reFerences
cooPerations & coMPLete soLutions
Gravity casting plants,
handling & more
Complete casting cells
KURTZ provides tiltable gravity and gravity casting machines which are available as single machine or turn-key
complete solutions / complete casting cells. The flexible
machine concept is easily adaptable to different customer requirements: low cost or high tech versions, maximum flexibility for frequent product changes or individual
customized solutions.
Ejectors with hydraulic
coupling
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. controlled, 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.
Cooling systems:
water-, air- or
mixed cooling
16
Machine, tilted by 90°, servohydraulic tilting motion, tilting
angle of up to 110° possible
What is valid for the low-pressure casting field is of
course also valid for KURTZ gravity and tiltable gravity
casting machines: complete solutions from one source
meeting your requirements!
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HistorY
185
Worldwide more than 1,100 people
177
The Kurtz Group
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KurtZ grouP & ManageMent sYsteM
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 satisfied. 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 flexibility and
customer proximity.
Where it all began:
The historical iron hammer works in Hasloch, Spessart,
remains in operation today as an industrial memorial.
The Kurtz Group
process model
Our control centre:
The headquarters of the Kurtz Group are in Wiebelbach –
not far from the iron hammer works in Hasloch.
Fine Traditions And A Bright Future
Business segments and products
since 1779
Foundry products
stencil Printers
shape Moulding Machines
Know-How transfer
Machining
soldering systems
Pre-expanders
used Machines and assembly service
Low-Pressure casting Machines
soldering tools
Blockmoulds
total Maintenance Quality service
sheet Metal technology
inspection systems
sheet Processing
innovation support
rework systems
engineering
Founded as iron hammer works in 1779 in Hasloch,
Spessart, the Kurtz Group has developed into an
internationally operating conglomerate. Today, we are
technological or world market leaders in many fields.
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.
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