Foundry | kovosvit mas, a.s.

www.kovosvit.cz

Production of castings from grey and ductile cast iron

Historical milestoneskovosvit mas, a.s. – basic information

02 | Foundry | production of castings from grey and ductile cast iron production of castings from grey and ductile cast iron | Foundry | 03

KoVoSVIT MAS, a.s. is a major producer of machine tools and castings from grey and ductile cast iron in the Czech republic and Central Europe. The MAS machine tools are known throughout the world – almost 70% of these are exported to over 50 countries. KoVoSVIT MAS, a.s. has two subsidiary companies: KoVoSVIT MAS Polska and KoVoSVIT ruS.

The development and production of machine tools and castings from grey and ductile cast iron in Kovosvit dates back over more than 70 years. The company has won many awards for its technical contributions towards the development of machine tools in the Czech republic.

The foundry is an independent part of KoVoSVIT MAS, a.s..

1939 Tomáš Baťa established the new MAS manufacturing plant focused on machine tools

1949 foundation of the KoVoSVIT national enterprise

1972 batch size of numerically controlled machine tools was initiated

1991 foundation of the joint-stock company KoVoSVIT, a.s.

2002 KoVoSVIT incorporated into the holding company KKCG (Karel Komárek Capital Group)

2010 KoVoSVIT MAS, a.s. became part of BonATrAnS GrouP HoLdInG LIMITEd

from 2011 ing. František Komárek became the only shareholder of KoVoSVIT MAS, a.s.

Vertical machine tools 5-axis vertical machining centres Gantry machining centres Horizontal machining centres Multi-functional turning-milling centres Highly productive centre lathes Centre lathes universal centre lathe with CnC control Special technologies – roller burnishing Palletization and robotization of machines Production of castings from grey and ductile cast iron

Foundry – production of castings from grey and ductile cast ironCastings are produced from the following materials:

grey cast iron (GG15 – GG35) ductile cast iron (GGG40 – GGG60)

The total annual capacity of the foundry is 12 000 tons of grey and ductile cast iron in the weight range per casting from 2 kg to 13 000 kg.In the last 10 years, the manufacturing process of castings and patterns was completely modernized. new automatic moulding line was put into operation in 2000 followed by equipment for the regeneration of foundry sand mixtures. Every year, the foundry invests in new technologies in order to be able to flexibly react to the requirements of its customers.

04 | Foundry | production of castings from grey and ductile cast iron production of castings from grey and ductile cast iron | Foundry | 05

Production options

CASTInGS ArE ProduCEd For THE FoLLoWInG InduSTrIES »

gearbox producers machine tools and forming machines (our customers are leading

producers of machine tools in Germany, Switzerland, Austria, Czech republic and the Slovak republic, England, Japan, uSA, Italy and other countries) automotive industry (our customers in the automotive industry are

in Germany, Italy, the Czech republic and other countries). agricultural machines producers of pumps, piping and armatures textile machines other industries

QuALITy SySTEM »

due to ensuring the quality, the quality control system was implemented in the foundry which includes the inspection of the input of raw materials, the whole flow of the production and the final inspection of the output castings. The whole process corresponds to the standards of quality inspection control; the foundryis a holder of the ISo 9001:2008 certificate.

The foundry includes a material laboratory and sand laboratory, there are records regarding the chemical and physical properties of individual materials and moulding mixtures evaluated and archived.

oTHEr oFFErEd SErVICES »

technological solution of castings for clients complete production of new patterns in own pattern shop using CnC technology. option to use patterns delivered by the customer and modified for current used foundry technology heat processing, stress relieving annealing coating of castings according to client requirements guarantee of material composition, chemical and physical properties of cast iron complete machining of castings within KoVoSVIT MAS, a.s. using the latest CnC machines

ProduCTIon oF PATTErnS »

production of complete patterns from wood, metal and a combination of wood, plastics or resin repair and modification of delivered patterns according to client requirements production of patterns on CnC machines

ProduCTIon oF CASTInGS »

Castings are produced according to individual weight categories, dimensions and batch sizes in three moulding shops:

Machine moulding shop – automatic moulding line

Production on Künkel-Wagner automatic moulding line with technology of natural send moulding mixture and AIrPrESS plus system.Production of cores on core shooting machines.

Appropriate for the production of major series .................................................50 pcs – 10,000 piecesWeight range....................................................2 kg – 80 kgMaximum dimensions of castings ..................800 × 650 × 380 mmMinimum wall thickness of .............................6 mmBatch size of .....................................................200 pcs – 500,000 pcs/year

Medium moulding shop – semi-automatic moulding lineProduction with the use of technology for furan mixtures prepared with GuT and FAT equipment.

Appropriate for the production of midrange series ...........................................2 pcs – 100 piecesWeight range....................................................100 kg – 1,300 kgMaximum dimensions of castings ..................2,400 × 1,200 × 550 mmMinimum wall thickness of .............................10 mmBatch size of .....................................................20 pcs – 1,000 pcs/year

Heavy moulding shop – manual moulding line

Production with the use of technology for furan mixtures prepared with GuT and FAT equipment.

Appropriate for the production of small series ..................................................1 pc – 20 pcsWeight range....................................................1,000 kg – 13,000 kgMaximum dimensions of castings ..................5,500 × 2,300 × 1,500 mmMinimum wall thickness of .............................12 mmBatch size of .....................................................10 pcs – 200 pcs/year

Melting shop

2 cupola furnaces, melting output 6 t/hour 2 low-frequency Siemens electric furnaces, volume 2 × 4 tons

Fettling shop – shot blasting of castings, grinding and final fettling

capacity – max. 48 t/day shot-blasting machine – Škoda, Schlick, Spencer, PTB staight and angle cutters, vertical cutters

Stocking shop and painting shop

2 roughing machines – portal rough machine, horizontal rough machine

dispatching department

packing and storage of castings according to customer's requirements

06 | Foundry | production of castings from grey and ductile cast iron production of castings from grey and ductile cast iron | Foundry | 07

Cooperation production

HEAT ProCESSInG »

Chemical-heat processing:

cementing in monocarb furnaces, diameter of furnace 500 × 1,550 mm depth of layer 0.1 to 1.5 mm material treatment, hardening in chamber and shaft furnaces

800 × 600 × 1,200 mm, diameter 700 × 2,300 mm annealing, tempering

High-frequency hardening:

shafts, bars, cover plate Medium-frequency hardening max. hardened diameter 200 mm max. length of hardened part 2,000 mm, weight 200 kg

Chemical surface treatment: matt chromium hard chromium blackening

TooL SHoP »

production of short run of small precise rotating and non-rotating elements, including heat processing

cooperative production of piece and small-batch size (turning, milling, exact drilling, round grinding, plain grinding, grinding of threads and worms)

special production gear wheels (direct and spiral gearing into modules 6) milled and grinded conical wheels, shaped worms and worm wheels production of inside grooves by tempering, extrusion and shaping rolling of outside threads off-center grinding of small parts grinding of wedge profiles

METAL SHEET SHoP »

complete production of bent and welded parts burning by laser on a TruMATIC L 3030 machine bending of parts on an edge-bending LVd CnC press up to the length

of 2.500 m welding and final fettling operations top coat in rAL shades according to client requirements

METroLoGy »

the control measuring centre is able to provide complex services for the inspection of parts using progressive measuring methods on three-coordinate machines and other measuring devices designed for verification of geometric deviations of form and position

protocol or calibration protocol can be issued for the inspected parts according to ISo standards

Main measuring equipment:

KMZ – G302020 – MAUSER – 3D three-coordinate measuring machine from Zeiss X / Y / Z = 3000 / 2000 / 2000, scanning head with the accuracy 3D = 4.5 + L/250 (μm)

MERLIN – 3D three-coordinate measuring machine from Feranti X / Y / Z = 750 / 750 / 750, with the accuracy 3D = 4 + L/350 (μm)

TALYROND 2 HOBSON – circle meter measurement of circularity with the accuracy of 0.2 μm

MUK 300 – circle meter

SIP 305 M – length meter measurement with the accuracy 0.4 μm

MIddLE MACHInEry »

machining of various steel groups, non-ferrous metals, plastics, castings of small and medium sizes from grey and ductile cast iron, aluminium alloys, forged pieces and metal parts using the latest CnC machines

production of rotating elements production of non-rotating elements

main machine tools:

MASTURN 40, 50, 70 CNC - universal machining centre diameter of machining max. 700, L max. 2000, flange and shaft parts

S 80 CNC - semi-automatic lathe diameter of tooling max. 400, driven tools, flange parts

SP 430 SY / 2 - semi-automatic lathe diameter of machining max. 440, driven tools, axis Y counter spindle, flange parts

SP 180 SY – semi-automated lathe diameter of machining max. 42, driven tools, machining from bar

Straightening bench for shaft parts diameter of straightening max.60, L max. 3500

SHV 120 - vertical lathe boring diameter of boring 24.7-106, L max. 850 (turning 1150)

FGS 40 CNC, NS 571 - console cutter X / Y / Z = 900 / 400 / 450

MCV 1016 QUICK – vertical machining centre X / Y / Z = 1016 / 610 / 710

MCV 1000 A + Walter rotary tilting table – 5-axis vertical machining centre diameter of the table 320 mm

MCV 1000 SPEED 5AX - 5-axis vertical machining centre diameter of the table 520 mm

MCU 630 V-5X - 5axis vertical machining centre diameter of the table 630 mm

WKV 100 - jig boring machine X / Y / Z = 1400 / 1000 / 700

BDU 250, 300 – slot grinder high precise grinding in an air-conditioned space diameter of grinded hole, max. 400

BUB 32, Fortuna - grinding machine for diameters ultraprecise grinding in air-conditioned room diameter of grinding max.320, L in centers max. 1500

BHU 40 A – universal grinding machine diameter of grinding max. 400, L in centres max. 2950 diameter of grinded hole, max. 300

thread grinding machine

HEAVy MACHInEry »

machining of medium and large box and flat elements, castings from grey and ductile cast iron, steel welded structures, including boring of precise holes and grinding of bases using the latest CnC machines

equipping with the latest CnC machine tools precise grinding hardening of linear guide on castings from grey cast iron 3d measurement

main machine tools:

MCV 1270 - vertical machining centre X / Y / Z = 1270 / 610 / 720

HEYNUMILL Ecoflex VD 2500 x 4000 / 4000 – portal machining centre X / Y / Z = 11000 / 3500 / 2250

VARIMAT-KOLB – portal machining centre X / Y / Z = 6000 / 2400 / 1100

MAZAK - portal machining centre X / Y / Z = 4000 / 2500 / 1300

MAZAK - horizontal machining centre (6 palettes 1000 × 1000 mm) X / Y / Z = 1640 / 1300 / 1220

HMC 630 - horizontal machining centre (2 palettes 630 × 630 mm) X / Y / Z = 1050 / 800 / 880

DIXI 410 - horizontal boring machine precise boring in air-conditioning space X / Y / Z = 1400 / 800 / 1000

WXH 100 CNC - horizontal boring machine precise boring in air-conditioning space X / Y / Z = 1200 / 800 / 1000

WKV 100 - jig boring machine X / Y / Z = 1400 / 1000 / 700

BPV 700, BRH 40 – flat-surface grinders w. 400 - 700 × 2000 mm

SKQ 20 CNC - vertical lathe diameter of turning max. 2000, L max. 1200

Horizontal planing machines w. 1600 - 3000 × 6,000 mm

WHN 9, WHN 13 - horizontal boring machines w. 2500 - 3500 × 900 - 2000 mm

SZ 1600 - portal grinding machine for guided surfaces width. 1600 × 6000 mm

WALDRICH - portal grinding machine for guiding surfaces width. 1250 × 4,000 mm

08 | Foundry | production of castings from grey and ductile cast iron production of castings from grey and ductile cast iron | Foundry | 09

Cooperation productionoTHEr oPTIonS »

Some workplaces operate in double-machine operation; multi-shift operation is ensured according to capacity needs - in this manner we can react flexibly to the utilization of particular workplaces.

In production and assembly, we have a quite numbers of additional, subsidiary and technologically machinery, which supports quality, increases labour productivity and expands our technological possibilities.

This machinery is also used to support our main working activities when solving the specific requirements of our customers.

kovosvit mas machine tools

10 | Foundry | production of castings from grey and ductile cast iron

Machining centres

Ver

tica

l

MC

V L

ine

mcv 754 ; 1016 quick mcv 750 mcv 1000 mcv 1270

Hor

izon

tal

HM

C L

ine

hmc 500 hmc 630

Gan

try

MC

U-M

MC

Lin

e

mcu 2000 mcu 3000 mmc 1500 mmc 1500 dt

Five-axis & Multi-tasking machines

Ver

tica

l

MC

V-M

CU

Lin

e

mcv 1000 5AX mcu 630 / 800v-5X mcu 630vt-5X

Mult

i-fu

nct

ional

MU

LTIC

UT

multicut 500 s / t

CNC lathes

Turn

ing

ce

ntr

es

SP L

ine

sP 180 sP 280 sP 430 sPh 50 cNc

Cen

tre

lath

es

MA

STU

RN

Lin

e

mAstuRN 550i cNc 800/1500 mAstuRN 550i livE tOOl cNc 1500 mAstuRN 820i cNc 2000/3000 mAstuRN 820i cNc - 4500

Spe

cial

tech

nol

ogie

s

RO

LLER

ROllER 2800 cNcMore videos at www.youtube.com/kovosvit

production of castings from grey and ductile cast iron | Foundry | 11

video

KoVoSVIT MAS, a.s.náměstí Tomáše Bati 419, 391 02 Sezimovo ÚstíCzech republic

T: +420 381 632 504, +420 381 632 537F: +420 381 744 519

E: pzk@kovosvit.cz

WWW.KoVoSVIT.Cz