Perucchini shell moulding foundry successfully supplies steel and cast iron castings for mobile and industrial hydraulic applications. This articles describes the industrialization of a non-magnetic hydraulic joystick for armoured military vehicles.
Perucchini shell moulding foundry successfully supplies steel and cast iron castings for the precision mechanical sector. This articles describes the positive development of a duty chain component realized in special austemperede cast iron.
Applications for marine environment require the use of special materials able to ensure advantages in terms of performances, mechanical resistance to wear and corrosion and, not least, the costs containment. For these reasons, Perucchini foundry developed, in co-design with the major manufacturers of the sector, many applications exploiting the peculiarities of the full shell moulding pouring process.
The strong development of the mining and mineral explorations in polar areas has required the set up of new products and solutions able to function at temperatures lower than 40 degrees below zero. These temperatures are not compliant with the traditional components made with standard commercial cast irons and steels, as, under a certain critical temperature, many kinds of steels lose their natural ductility and become extremely fragile and subject to breakdown.
The most recent development trends in the mobile hydraulic field are characterized by the need of significant reductions of weights, dimensions and costs. For this purpose it becomes necessary to develop new hydraulic solutions with higher working pressures, with peaks over 500 bars instead of the standard 350 bars.
Perucchini’s full shell moulding foundry is synonymous for precision as it allows to obtain rough steel or cast iron castings with almost finished shapes. They are comparable, both for quality and tolerances, to the lost wax process castings, but with lower costs, thanks to the know-how and the continuous innovations developed through long lasting supplies of complex parts to most exigent customers.
The casting of parts in steel needs careful control operations to grant a product in conformity with the required technical specifications.
Steel is a material that tends to form defects due to the loss of volume during the liquid-solid transition. Typically, these are located in the heart, not visible outside, and are of variable size depending on the geometry of the piece...
The introduction of the foundry simulation software for the design of new castings gets many benefits:
- achievement of high quality standards
- best efficiency in the design analysis
- reduction of the time-to-market
- simplified research of innovative shapes and solutions...
During the project of a casting, the co-design between the foundry and the developer is an important activity: the experience of the foundry combined with the designers need to obtain specific characteristics allow to manufacture casted parts with controlled machining allowances at lower production costs (1).
The dimensional tolerances are met by the study of the proper feeding of the casting...
Recent innovations in the field of castings allow to obtain cast iron parts with a wear resistance comparable to the traditional and more expensive materials: hardened and nitrided steel, Cr-hard cast irons.
The liquid metal is prepared with a specific metallurgy and the resulting castings undergo the austempering heat treatment, namely the heating to 850°C and the subsequent tempering...
The use of castings for mechanical components can reduce and simplify their subsequent machining.
The greater the precision of the casting is, the smaller the machining operations are.
Among the forming processes applied in foundries, the Shell Moulding is the one that allows the best precision: reduced dimensional tolerances, complex shapes, low surface roughness.
Two glued half shells constitute the form where the liquid metal is poured...
Perucchini is a known foundry for precision castings, cast iron & steel, in full shell moulding technology. The “full” shell moulding process consists in casting liquid metal inside shells with internal cores, both formed with sands treated and coated with thermosetting resins
- leader in full shell moulding technology
- wide range of steel and stainless steel
- high precision and extended weight range
- small thicknesses and complex shapes for special castings
- close tolerances with smooth surfaces stand for less machining operation