Foam cutting machines in metallurgy

Machine tools for cutting PSP foam have found their application in metallurgy due to the technology of casting according to gasified models (LGM).

A computer model created in advance is cut out of polystyrene foam, over which metal is subsequently spilled. Foam plastic under the influence of high temperatures burns out, allowing the metal to fill the volume, repeating the product with high accuracy.

Gasified casting is a technology that makes it possible to obtain castings in accuracy equal to investment casting at a cost level comparable to casting into earth. Gasified casting as a new technological process appeared in the mid-50s. Its main purpose was to improve casting accuracy while significantly reducing equipment and material costs compared to investment casting technology.

The gasified casting method (LGM) has a number of advantages:

• Dramatically reduce equipment costs

• Reduce the number of technological steps

• Due to the use of recycled quartz sand as a molding material and strengthening of the form by vacuum, the use of rods and equipment for their manufacture is eliminated

• Reduce finishing operations on castings

• Minimize production waste

• Reduce labor costs by 2-4 times

• Reduce electricity consumption by 2-3 times

• Reduce and make optimal use of production space

• Reduce the cost of auxiliary materials by 3-5 times.

Calculation of the cost on the example of a screw pile

Objective: It is necessary to cut a screw pile nozzle.

Billet: PSB-S-25 1200x1000x2000 mm (2.4 cubic meters)

Nozzle dimensions: 350x350x330 mm.

Calculations (for a rough estimate of profitability):

From 1 block, 45 nozzles are obtained.

The cost of foam in Novosibirsk: 3000 rubles / cubic meter.
The cost price of polystyrene for 1 nozzle is 2500 rubles / cubic meter. * 2.4 cubic meters / 45 = 160 rubles.
Cutting time for 1 nozzle 1 h 24 min.

Recommended equipment (options):

- SRP-3223 "Mini" with a rotary table - 192,000 rubles.

- SRP-3221 "MaxiUniversal" with a rotary table - 209,000 rubles.