Holsby Group DEVELOPMENT CASTING MACHINING

Transcription

1 Holsby Group DEVELOPMENT CASTING MACHINING

2 Holsby Group The group that consists of Holsbyverken with the subsidiaries Älmhults Gjuteri, Nordcast, Rosenfors Bruk and Vcast, is a modern business group that covers development, casting and machining. The key part of our customers is within manufacturing industry with the need of castings weighing from 1 kg to kg. We have a turnover of approximately 300 million SEK and have 120 employees. Through our composition of own foundries, machining, trading and engineering company, we can be involved in all parts of the products lifecycle from development through prototype, production and at last aftermarket. We have the knowledge and the possibility within the group to offer the entire production chain from casting to finished product. Our extensive experience and broad competence in combination with investments in modern simulation and 3D software means that we have all the conditions to meet the expectations of our customers. The business is certified according to ISO 9001 and ISO In addition to these we are certified to produce grey and ductile iron castings for marine use and for pressure equipment according to PED. 2 Quality / Environment The aim for Holsbyverken is to maintain such an environmental and quality level that it defines an essential reason for buying castings from us. Concurrently, we are working towards contributing to a satisfying working environment and a positive, long-term and sustainable social progress.

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4 PRODUCTION Machine moulding HWS-Seiatsu Moulding size 640x510x250/250 mm Casting weights from 1-75 kg Handmoulding Moulding size 1400x1000x450/450 Casting weights up to 1000 kg Melting shop 2x ABB 5,0-tonne high-frequency furnaces with 1,800 kw output 1x ABB 5,0-tonne high-frequency furnace with 3,000 kw output Core shop Core production in 4 automatic machines Laboratory 1x spectrolab Analysis and structure control Pattern shop Manufacturing, customising and assembling of patterns Casting simulation and 3D modelling Uses casting simulation software MagmaSoft and CAD software SolidWorks 4

5 Holsbyverken Holsbyverken is a modern foundry with production of grey and ductile iron. We have a long tradition within foundry industry. The company was founded in 1947 in Holsbybrunn and is since 1963 situated in Vetlanda. Large investments have been done in production and casting simulation equipment in order to meet highly set demands when it comes to environment, quality and productivity. The production capacity is tonnes of castings per year of weights from 1 to kg. The customers are mostly within manufacturing industry. The business is certified according to ISO 9001 and ISO In addition to these we are certified to produce grey and ductile iron castings for marine use and for pressure equipment according to PED. Material GJS Vikt 3,5 kg Holsbyverken is parent company to Nordcast, Älmhults Gjuteri, Rosenfors Bruk and Vcast. Material GJL-200 Vikt 9 kg Material GJS Vikt 105 kg Material GJS Vikt 28 kg MATERIAL Grey iron GJL-200 (0120) GJL-250 (0125) GJL-300 (0130) GJL-HB195 (0217) GJL-HB215 (0219) GJL-HB235 (0221) Ductile iron GJS (0717) GJS (0727) GJS (0732) GJS (0737) We deliver according to the standard EN 1561:2011 grey cast iron and EN 1563:2012 ductile cast iron. HOLSBYVERKEN Box 33, Vetlanda, Sweden Visit: Upplandavägen 17, Vetlanda +46 (0) info@holsbyverken.se www. holsbyverken.se 5

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7 Nordcast Nordcast offers deliveries of iron and steel castings to competitive cost in the range of 1 kg to kg. The company was founded in 1979 and has extensive experience of trading with castings. The suppliers are carefully chosen concerning technical competence and equipment. The key part of the suppliers are certified according to ISO Our strength is that we can be part of the development in order to offer a fast startup through our Swedish foundries in the group. They can also be the backup supplier when the product has proceeded to serial deliveries. We secure little time of delivery through stock-piling towards blanket release. Material GJL-200 Weight 12 kg The business is certified according to ISO 9001 and ISO Nordcast is a subsidiary to Holsbyverken. Material G20Mn5+N Weight 8 kg Material GJL-HB215 Weight 28 kg Material GJS Weight 12 kg MATERIAL Grey iron GJL-200 (0120) GJL-250 (0125) GJL-300 (0130) GJL-HB195 (0217) GJL-HB215 (0219) GJL-HB235 (0221) Ductile iron GJS (0717) GJS (0727) GJS (0732) GJS (0737) Steel We can provide the most material according to EN NORDCAST Box 17, Vetlanda, Sweden Visit: Upplandavägen 17, Vetlanda +46 (0) info@nordcast.se www. nordcast.se 7

8 PRODUCTION Machine moulding GF+ Air Impact Moulding size 900x700x300/300 Weights from kg Melting shop 2 pc ABB HFD 4 tonnes Core shop Core production in 2 automatic machines Pattern shop Manufacturing, customizing and assembling of patterns Fettling shop 2 pc shotblasting +GF+ Casting simulation and 3D modelling Uses casting simulation software MagmaSoft and CAD software SolidWorks Laboratory 1 pc Spectrolab for chemical analyses Equipment for structure tests 8

9 Älmhults Gjuteri Älmhults Gjuteri is a modern foundry producing grey and ductile iron in short and medium series. Due to a long tradition within the foundry industry we have gained our competence and experience. The production capacity is tonnes of castings per year weighing from 10 to 150 kg. The customers are represented by manufacturing, vehicle, building and construction industry. We have a large flexibility in order to meet the demands and needs of our customers. Material GJL-HB195 Vikt 30 kg The business is certified according to ISO 9001 and ISO 14001, and to produce pressure equipment according to PED. Älmhults Gjuteri is a subsidiary to Holsbyverken. Material GJS Vikt 20 kg Material GJS Vikt 55 kg Material GJS Vikt 63 kg MATERIAL Grey iron GJL-200 (0120) GJL-250 (0125) GJL-300 (0130) GJL-HB195 (0217) GJL-HB215 (0219) GJL-HB235 (0221) Ductile iron GJS (0717) GJS (0727) GJS (0732) GJS (0737) We deliver according to the standard EN 1561:2011 grey cast iron and EN 1563:2012 ductile cast iron. ÄLMHULTS GJUTERI Box 612, Älmhult, Sweden Visit: Stallgatan 2, Älmhult +46 (0) info@gjuteriet.com www. gjuteriet.com 9

10 PRODUCTION Horizontal machining 3 pcs Horizontal machining center Work space: 1000x900x1000 Pallet size: 630x630 Equipped with 10 pcs pallet system, pcs tool space, measuring probe. CNC-Lathes 10 pcs CNC-Lathes Works space: max Ø900x1500 Multifunctional machining 1 pcs Lathe, Multus B400C Work space: Ø710x1500 Measuring machines Measuring machine X:900, Y:1200, Z:800 Other Deep hole drilling, assemblying and pressure testing. 10

11 Rosenfors Bruk Rosenfors Bruk is active within machining of above all, iron and steel. The company was founded already in 1802 and is situated in Rosenfors 15 km south of Hultsfred. Large investments in machining equipment have been made in order to increase capacity and to meet increased quality and productivity demands. The combination of competence and experience means that we can participate in the design of products in order to develop a cost-effective and qualitative good product as possible together with the customer. The customers are above all within the manufacturing industry. Material GJL-HB195 Vikt 3,0 kg The business is certified according to ISO 9001 and ISO Rosenfors Bruk is a subsidiary to Holsbyverken. Material GJS Vikt 27,5 kg Material GJS Weight 64 kg Material G20Mn5+N Weight 10,8 kg Through our broad knowledge within machining we deliver the best technical solutions considering both function and production. We work with series in the range of up to products per year. ROSENFORS BRUK Rosenfors, Sweden Visit: Emmenäsvägen, Rosenfors +46 (0) info@rosenforsbruk.se www. rosenforsbruk.se 11

12 WORKFLOW developing of cast components SOLIDIFICATION SIMULATION GATING DESIGN CASTING SIMULATION 12

13 Vcast Vcast is an engineering company within the foundry industry. We work above all with preparing input for the production of models, casting simulation and design. We use modern CAD softwares and Magmasoft for casting simulations. Design We have the knowledge to design castings from scratch, further develop or give feedback on an existing design in order to make it suitable for casting. Casting simulation Casting simulation is a valuable tool for foundries as well as for buyers of cast goods. With this tool we can localise the problem areas that may develop in castings, meaning that changes can be done early in the developing phase when it comes to design and preparation process. This leads to shorter lead-time, product is given better quality and the risk of complications decreases. Education We have the possibility to offer education within foundry technology and casting design. Considering your needs and requests we can provide an education suited for you. There is also the possibility of visiting our foundry or machine shop. Casting simulation of part Pattern equipment assembled on pattern plate Our close collaboration with the other companies in the group; the foundries Holsbyverken and Älmhults Gjuteri and the machining company Rosenfors Bruk, makes it possible for us to be a part of the entire process from design to finished product. VCAST Box 33, Vetlanda, Sweden Visit: Upplandavägen 17, Vetlanda +46 (0) www. vcast.se 13

14 Change of production method From our experience it is often a potential of cost savings by switching to casting as a production method. Casting also gives other possibilities when it comes to design, function and appearance. Through our group of own foundries, machining, trading and engineering company, we have broad knowledge and can actively contribute to the development process. Following shows four examples where the production method is switched to casting. Example 1 Welding Casting 9 components, welded together Weight 7,9 kg Produced in one piece Weight 7,84 kg 14 Cost reduction: 56%

15 Example 2 Welding Casting 6 components, welded together Weight 11 kg Produced in one piece Weight 14,7 kg Cost reduction: 21% Example 3 Welding Casting 6 components, welded together Weight 10,6 kg Cost reduction: 18% Produced in one piece Weight 9,9 kg Example 4 Sheet metal cutting Casting Weight 24,9 kg Cost reduction: 31% Produced in one piece Weight 24,5 kg 15

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