your expert partner in the field of casting

Your expert partner in the field of casting

Blocked for new applications / Fuer Neuanwendung gesperrt

2 Casting | History

The future needs the past

Quality born of experience: Rexroth Guss has been a global castings supplier for 200 years

1795Georg Ludwig Rexroth commissions an iron hammer mill in Elsavatal, in Germany's Spessart mountain region

1850The hammer mill in Lohr is commissioned Rexroth's headquarters are relocated to Lohr

1952The company starts to specialize in pressure-tight castings for the manufacture of stan-dardized hydraulic components in the Rexroth Hydraulics division

2001Bosch Rexroth AG is launched, specializing in drive and control technologies

2003A comprehensive investment and restructuring program is implemented Level of investment since 2003 > EUR 50 million

2010Core molding is automated

20123D core printer commissioned to produce prototypes, small series, and spare parts


3 Innovation and expertise | Casting

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Innovation and expertise

Castings from Rexroth combine unparalleled global expertise with state-of-the-art processes

Whether you need melting, casting or alloying, we produce to the highest level of precision and dimen-sional accuracy with consistently high quality and effi-ciency in one of Europe's most advanced foundries.

With our flexible production capabilities and unparalleled level of experience, we guarantee you customized and optimized solutions. It is worth your while to involve us right from the conception of your cast parts.

The designs are based on 3D data, which can either be provided by you or generated by Bosch Rexroth using a GOM® optical measuring system.

The 3D data is used to make all technical casting additions (drafts, core bearings, shrinkage, etc.).

With the aid of the Magmasoft® software, solidification simulations can be carried out on the computer in advance so that the casting result can be optimized prior to the actual manufacturing process.

Our experts are happy to help you develop the opti-mum solution for your company.

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4 Casting | New technology

Together with our customers, we find solutions for almost every challenge by combining a unique variety of the latest technologies with our expertise.

Quickly available prototypes play an important role in the development of new components. Development time and thus development costs are reduced, thereby providing competitive advantages.

We cover the entire process chain in-house and provide you with a full service from a single source, thanks to facilities such as the two 3D printers we have owned since 2012.

Technology redefined

3D printing technology for prototypes, small series, and spare parts

The production time for a usable casting product can be reduced from 12-14 weeks to 2-4 weeks.

We also use this technology for small series parts and the production of prototypes. The advantages of this process are particularly noticeable in highly complex geometries.

Core assembly sites and drafts can be omitted, undercuts no longer pose a problem, and geometry changes can be implemented very quickly.


5 New technology | Casting

Spare parts production3D data is generated from a worn or defective part and then touched up by our developers. You will then receive the newly cast, unmachined part within 2 to 4 weeks.

For any applicationWith our state-of-the-art technology and dedicated employ-ees, we will support you from the planning stage through to delivery. There is no substitute for our experience – it simply grows with the latest technology.

From planning to delivery

Fast solutions for complex requirements from a single source

Customer Customer

Conventional process sequence

Engineering

Engineering

DesignCalculationSimulation

CastingHeat

treatment

Internal 3D printing Core Mold

Core and mold production

Tool making Production

Process time reduced by up to

10 weeks

Production

Process sequence with 3D printing process

Data input

Optical layout acquisition

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6 Casting | Molding machine casting

▶ Production unit weight: 5 kg to 200 kg ▶ Batch size: min. 20 boxes ▶ High reproducibility thanks to modern molding plant ▶ Fine-grained, homogeneous structure guarantees high

mechanical material properties ▶ CAD/CAM-fabricated modeling equipment ▶ Mechanical preparation

High-quality, precisely manufactured, metal and plastic modeling equipment and core boxes provide the highest level of dimensional accuracy and consistently high quality. We use croning or cold-box cores, depending on the geom-etry and required core stability. In many cases, a combina-tion of these two core systems is particularly economical.

Bosch Rexroth's tried and tested core technology guaran-tees flow-optimized inner contours. The size of the compo-nents is significantly reduced and elaborate, mechanical machining operations are reduced to a minimum.

We provide extensive consulting right from the develop-ment phase in order to help you determine the best casting technique for your needs.

Molding machine casting

Precision in series: In our fully automatic molding plant, we produce high-precision series parts made from gray and nodular cast iron, as well as special alloys.


7 Molding machine casting | Casting

See for yourself: ▶ Many years of experience in gating, casting and feeding

technology ▶ Dimensionally accurate cores for complex internal contours ▶ Molding plant with a molding box size of

1030x890x300/300 mm ▶ Extensive consulting which starts in the design phase ▶ Computerized order processing and PPS-controlled

production ▶ Quality management throughout the production process

and maximum process reliability

Molding machine casting material properties

Cast iron with lamellar graphite according to DIN EN 1561

EN-GJL Brinell hardness HBW-5/750

EN-GJL -200 125 ‒ 195

EN-GJL -250 160 ‒ 235

EN-GJL -300 180 ‒ 255

Cast iron with spheroidal graphite in according to DIN EN 1563

EN-GJS Brinell hardness HBW-5/750

EN-GJS-400-15 135 ‒ 185

EN-GJS-400-18 130 ‒ 175

EN-GJS-500-7 150 ‒ 230

EN-GJS-500-14 170 ‒ 215

EN-GJS-600-3 180 ‒ 270

Our possibilities

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Special alloys and other materials for special applications are available on request


8 Casting | Permanent mold casting

In permanent mold casting, the molten iron is poured into special iron permanent molds. This enables us to meet many of the criteria which are typical of steel, and offer numerous possibilities for creating individual molds.

The positive structural properties and consequently shorter processing times significantly reduce your product costs. This technology has been proven in many fields, including the pharmaceutical industry, mechanical engineering and shipbuilding, and the construction industry.

▶ Production unit weight: up to 5 tons ▶ Fine-grained homogeneous structure ▶ High strength ▶ Mechanical preparation

With the aid of the Magmasoft® software, solidification simulations can be carried out on the computer in advance so that the casting result can be optimized prior to the actual manufacturing process.

Permanent mold casting

Ideas at their very best: Permanent mold casting enables castings to be produced with excellent mechanical and physical material properties and near-net-shape dimensions.


9 Permanent mold casting | Casting

Ingots from RexrothCast in iron permanent molds, our ingots, round rods and bushings have an particularly fine and homogeneous cast structure.

This results in excellent mechanical properties, which are especially advantageous for complex milling and boring operations.

We produce permanent mold cast ingots with a weight of up to 8 metric tons per piece.

In order to offer our customers the most flexible and cost-effective procurement source possible, we stock EN-GJS-400-18 ingots (620x620x1050 mm), which we can cut according to customer requirements.

GJS-quality spheroidal chill cast iron in accordance with DIN EN 1563

EN-GJS Brinell hardness HBW-5/750

EN-GJS-400-18K 130 – 180

EN-GJS-500-7K 170 – 240

EN-GJS-600-3K 200 – 290

EN-GJS-500-14K 170 – 215

EN-GJS-600-10K 190 – 230

EN-GJS-700-2K 220 – 300

GJL-quality HK special casting in accordance with DIN EN 1561

EN-GJL Brinell hardness HBW-5/750

EN-GJL -200K 120 – 180

EN-GJL -250K 180 – 240

EN-GJL -300K 200 – 290

The subtle difference

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10 Casting | Flashing/grinding/lapping

In cooperation with leading machine manufacturers and renowned ball producers, Bosch Rexroth develops special casting qualities for the machining of balls and surfaces. We supply nearly all the world's best-known ball and wafer producers and are the original equipment manufacturer for a wide range of machine manufacturers.

Produced in a special permanent mold casting process, the Rexroth plates are characterized by the following criteria:

▶ Cavity-free, homogeneous basic structure. Minimal differences in hardness across the entire cross section

▶ Even graphite formation in shape and size over the entire cross section

▶ High stability

Flashing, grinding and lapping plates

Well-rounded products: Machined and ready to install in ball, flat lapping, and double disc grinding machines

Thanks to these special properties, the long service life, excellent removal rate and good machinability of Rexroth plates will give you excellent ball qualities of up to grade G3 according to ISO 3290. Our special designs and in-house developments are built according to customer drawings.

Casting qualities from our standard range:

Flashing and grindingRexroth special alloy, hardenable250 – 310 HBW

Rexroth special alloy, hardened 470 – 520 HBW or 560 – 610 HBW

Pre-lappingRexroth HK special casting EN-GJL -250K180 – 240 HBW

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Final lappingRexroth HK special casting EN-GJL -200K120 – 180 HBW

Rexroth spheroidal chill cast iron EN-GJS-400-18K130 – 180 HBW

Permanent mold casting material properties (found on separately cast sample)


11 Flashing/grinding/lapping | Casting

HK special casting in accordance with DIN EN 1561 and DIN EN 1563

Brinell hardness HBW-5/750 Usage

HK special casting, hardened, CR alloyed 1* GGK-H 560 – 610 Flashing and grinding

HK special casting hardened 1* GGK-H 470 – 520 Flashing and grinding

HK special casting, hardenable, unhardened 1* GGK-H 250 – 310 Flashing and grinding

HK special casting, ferríte perlític

1* GGK-FP 2* EN-GJL -250K 180 – 240 Pre-lapping

HK special casting, ferríte 1* GGK-F 2* EN-GJL -150K 120 – 180 Final lapping

Spheroidal chill cast iron 1* GGGK402* EN-GJS-400-18K 130 – 180 Final lapping

Spheroidal chill cast iron 1* GGGK702* EN-GJS-700-2K 250 – 310 Grinding

1* Designation in accordance with VDG information sheet W432* Designation in accordance with DIN EN 1561/1563

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12 Casting | Kolene

Suitable for cleaning: ▶ Complex inner geometries ▶ Precision cast parts that cannot be cleaned conventionally ▶ Desanding, descaling and removing graphite from com-

ponents made of cast iron

With the help of 480 °C salt baths, all non-metallic residues are broken down in a continuous process lasting seven hours. This process, which is unique in Germany, is especially useful in helping us to clean residues from delicate channels.

The fully automated control system ensures high process reliability. A high level of component cleanliness forms the basis of low-wear mechanical processing and reliable functionality.

Kolene

We have an electrochemical process that breaks down sand residues and reduces oxides on cast parts.


13 Testing and measuring technology | Casting

Our comprehensive quality management system ensures that our cast products are of a consistently high quality. First, the raw material must be selected carefully. Next, our products need to undergo numer-ous examinations and metallurgical tests before leaving our premises as Rexroth-quality castings.

We analyze the entire process and research new materials in our laboratory. Extensive metallurgical tests constitute a key pillar of our continuous improvement process.

Optical measuring machines enable us to digitize existing components and generate 3D data sets. We can create 3D measurement protocols for you on request.

Mold tools are continuously monitored for wear using these measuring instruments. This preventive mainte-nance guarantees high process reliability.

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Guaranteed quality: The final inspection includes not only all the necessary mechanical tests, but also non-destructive materials testing using ultrasound and endoscopy.


14 Casting | Center of competence

Under the acronym Center of Competence, we support companies in all matters relating to foundry technology.

We apply our broad range of expertise and work together with you on solutions to address all the challenges posed by the provision of castings.

In our capacity as a CoC, we see ourselves as a consulting service provider whose objective is to supply your company with the in-depth knowledge that comes from our 200 years in the field of foundry technology.

Our experience – your success

▶ Conception of the cast part ▶ Review/revision of existing casting designs ▶ Tool designs ▶ 3D scanning and simulations ▶ Rapid prototyping ▶ Quality improvements incl. fundamental investigations ▶ Samplings ▶ Supplier localization and qualification ▶ Technical supplier support ▶ Drafting and negotiating contracts

Rexroth Center of Competence (CoC)


15 Environment and quality | Casting

Protecting the environment and conserving resources are an integral part of Bosch Rexroth's corporate policy. These principles apply to both production and product design. They help us to minimize the use of resources and environmental pollution throughout the entire life cycle – from the product concept, development, production and operating life right through to recycling.

As such, the Rexroth foundry is one of the first to operate according to the DIN EN ISO 50001-certified energy man-agement principles. All the materials we use are selected for both their technological aspects and their emissions. The focus here is on high environmental compatibility and recyclability.

Certified quality

The certification of our quality management system confirms that we meet all the requirements of DIN EN ISO 9001:2008. We also have approval from the following classification societies:

▶ Det Norske Veritas ▶ Lloyd´s Register of Shipping ▶ TÜV Süddeutschland in accordance with

“AD2000 information sheet W 0 / TRD 100” ▶ Germanisch Lloyd ▶ OHRIS (OHSAS 18001) ▶ DIN EN ISO 9001 ▶ DIN EN ISO 14001:2004 ▶ DIN EN ISO 50001: 2011

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Occupational safety and environmental protection management systems that have been in operation for many years demonstrate excellent achievements time and again.

Gray iron – green production


Bosch Rexroth AGRexroth GussZum Eisengießer 197816 Lohr, DeutschlandTel +49 9352 18 - 0Fax +49 9352 18 - [email protected]/guss

RE 90118/04.15© Bosch Rexroth AG 2015


your expert partner in the field of casting

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