FOUNDRYProduction of castings made of grey and ductile cast iron

www.kovosvit.cz

KOVOSVIT MAS, a.s. — basic informationKOVOSVIT MAS, a.s. is one of the most important manufacturers of machine tools and casts made of grey and ductile cast iron in the Czech Republic and Central Europe. The MAS machine tools are known all over the world – almost 70% of the production is designated for export. The company sells its products to more than 50 different countries. KOVOSVIT MAS, a.s. has two subsidiary companies: KOVOSVIT MAS Polska and MTE KOVOSVIT MAS.

The tradition of the production and development of machine tools and casts made of grey and ductile cast iron in Kovosvit dates back more than 70 years. The company has been awarded many prizes for technical contribution to the development of machine tools in the Czech Republic.

A foundry is an independent part of KOVOSVIT MAS, a.s.

Castings are exported to:

Germany, Switzerland, Czech and Slovak Republics, Russia, Great Britain, Italy, Sweden, Finland, France, Austria, Slovenia, Luxembourg and others.

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Historical milestones1939 Tomáš Baťa founded a new production plant called MAS, which specialized in the production of machine tools

1949 establishment of a state enterprise called KOVOSVIT

1972 commencement of the serial production of numerically controlled machine tools

1991 establishment of joint stock company KOVOSVIT, a.s.

2002 KOVOSVIT joins the KKCG holding group (Karel Komárek Capital Group)

2010 KOVOSVIT MAS, a.s. becomes a part of the BONATRANS GROUP HOLDING LIMITED

from 2011 Mr. František Komárek becomes the only and exclusive owner of KOVOSVIT MAS, a.s.

First casting, 1940

FOUNDRY PATTERN SHOP MACHINING SHOP

Castings are manufactured by the following materials:— Grey cast iron (GG15 - GG35)

— Ductile cast iron (GGG40 - GGG60), GGG40.3 LT

The total annual capacity of the foundry is 14 000 tons of grey and ductile cast iron. The weight of the casting ranges between 2 and 14,000 kg.

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TECHNOLOGICAL PREPARATION AND CONSULTING

PATTERN SHOP

MOULDING SHOPS

MATERIALS

MELTING AGGREGATES

MACHINING

OTHER SERVICES

QUALITY SYSTEM

Casting technology, machining, optimal solutions for customers

Pattern shop— production of complete pattern devices

made by wood, metal and combinations of wood with metal, plastic materials or resins

— option to use patterns supplied by customers and their adjustment for the current foundry technology

— pattern production on CNC machines

We prepare the optimal solution for your castings and machining to the highest quality with the lowest production costs.

We propose design modifications and hold consultations whereby we use the most appropriate materials for your products.

When preparing the technology, we use DraftSight software and NX 5.8 to prepare 3D data and the subsequent production of modern CNC machinery.Using a simulation program for MAGMA SOFT casting and solidification, we optimize the internal quality of casting and resolve any potential problems before producing the castings.

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Moulding lines

MEDIUM MOULDING SHOP— semi-automatic moulding line

Production that utilizes the technology of self-hardening furan mixtures.

Suitable for the production of middle series 2  – 100  pcs

Weight range 100 – 1.300 kg

Maximal dimensions of the castings 2.400 × 1.200 × 550 mm

Minimal wall thickness 10  mm

Serial production 20  – 1.000 pcs/year

HEAVY MOULDING SHOP— manual moulding

Production that utilizes the technology of self-hardening furan mixtures.

Suitable for the production of small series 1 – 20  pcs

Weight range 1.000 – 14.000 kg

Maximal dimensions of the castings 5.500 × 2.300 × 1.500 mm

Minimal wall thickness 12  mm

Serial production 10  – 200 pcs/year

Castings are made pursuant to individual weight categories, dimensions and series sizes in three moulding shops:

MECHANICAL MOULDING SHOP— automatic moulding line

Production on the automated Künkel-Wagner moulding line, utilizing the technology of bentonite moulding mixture and the AIRPRESS plus system. Production of cores on core shooting machines.

Suitable for the production of large series 50  – 10.000  pcs

Weight range 2  – 80  kg

Maximal dimensions of the castings 800 × 650 × 380 mm

Dimensions of the line frame 850 × 700 × 500 mm

Minimal wall thickness 6  mm

Serial production 200  – 500.000 pcs/year

Materials

MAGMA5 simulation software— MAGMA5 simulation software is developed and supplied by

MAGMA GmbH.

— MAGMA5 simulation software is focused on the simulation of foundry technologies and related technologies.

— The simulation makes it possible, for example, to monitor the filling of the mold cavity by melt, whether the filling is complete and that there is no absorption of the gas into the melt, etc. It is also possible to monitor the progress of the solidification of the melt in the form and to analyze the place where the melt solidifies as the last and that the solidification is correctly rectified.

— Through the use of simulation software, problems can be detected in the proposed manufacturing technology that could lead to defects in cast pieces, these problems analyzed and treatment technology proposed even before the actual production patterns and the cast piece itself. This makes it possible to save costs on adjustment patterns and production. As a result, costs for modification of the model equipment and for the production of testing series can be saved and the risk of defects occurring in cast pieces minimized as the technology is optimised by the simulation software.

— The new version of MAGMA5 software comes with an automatic optimising function, which is based on the fact that the software, on the basis of the input parameters and the required outputs entered by the technologist, proposes a wide range of potential technology solutions that fulfil the stated requirements. From these, the technologist selects the proposal that from an economic and technical viewpoint is the most suitable for the stated foundry.

MATERIAL TABLE

Grey cast iron:

EN DIN ČSN ASTM

EN-GJL-150 GG 15 42 24 10 Class 25

EN-GJL-200 GG 20 42 24 15 Class 30

EN-GJL-250 GG 25 42 24 25 Class 35

EN-GJL-300 GG 30 42 24 30 Class 40

EN-GJL-350 GG 35 42 24 35 Class 45

We produce grey cast iron utilizing the duplex technology; we melt the cast iron in cupola furnaces. Subsequently, we modify it to the required quality in electric induction furnaces.

Ductile cast iron:

EN DIN ČSN ASTM

EN-GJS-400-15 GGG 40 422304 60-40-18

EN-GJS-400-18LT GGG 40.3 422314 60-40-18

EN-GJS-500-7 GGG 50 422305 70-50-05

EN-GJS-600-3 GGG 60 422306 80-60-03

We produce ductile iron using the Tundish Cover irrigation method or by solid profile.

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Melting aggregates— 2 cupola furnaces, melting capacity of 6 tons / hour— 2 low-frequency Siemens electric furnaces, melting capacity of 4 tons / hour— medium-frequency INDUCTOTHERM furnace, melting capacity of 6 tons / hour

Machining

MEDIUM MECHANICS— machining steels of various qualities, non-ferrous metals,

plastics, small and medium size casting from grey and ductile cast iron, aluminium alloys and forged and firing pieces, using the latest CNC machines

— production of rotating parts— production of non-rotating parts

MAIN MACHINES:

MASTURN 40, 50, 70 CNC - universal centre lathe maximum machining ø of 700, maximum L of 2000, flange and shaft parts

S 80 CNC - semi-automatic lathe machine maximum machining ø of 400, driving tools, flange parts

SP 430 SY / 2 - semi-automatic lathe machine maximum machining ø of 440, driving tools, axis Y, counter-spindle, flange parts

SP 180 SY – semi-automatic lathe machine maximum machining ø of 42, driving tools, rod machining

Straightening bench for shaft parts maximum strengthening ø of 60, maximum L of 3500

SHV 120 - horizontal boring lathe boring ø of 24.7-106, maximum L of 850 (1150 by turning)

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

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

MCV 1000 A + revolving folding desk Walter – 5-axis vertical machining centre desk ø of 320 mm

MCV 1000 SPEED 5AX - 5-axis vertical machining centre desk ø of 520 mm

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

MCU 630 V-5X - 5-axis vertical machining centre desk ø of 630 mm

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

BDU 250, 300 – hole grinder highly accurate grinding in an air-conditioned environment maximum ø of ground holes of 400

BUB 32, Fortuna - diameter grinder highly accurate grinding in an air-conditioned environment maximum grinding ø of 320, maximum L in centres 1500

BHU 40 A – universal grinder maximum grinding ø of 400, maximum L in centres 2950 maximum ø of ground holes 300

Thread grinder

HEAVY MECHANICS— machining medium-size and large box and flat parts and casts

made of grey and ductile cast iron, complete machining of steel welded constructions, including drilling precise holes and grinding bases, utilizing the latest CNC machines

— equipping with the latest CNC machining tools— precise grinding— quenching slideways on casting made of grey iron cast— 3D measurements

MAIN MACHINES:

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

HEYNUMILL Ecoflex VD 2 500 × 4 000 / 4 000 – 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 / 3600 / 710 mm

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

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

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

DIXI 410 - horizontal boring machine, accurate drilling in an air-conditioned environment X / Y / Z = 1400 / 800 / 1000

WXH 100 CNC - horizontal boring machine, accurate drilling in an air-conditioned environment X / Y / Z = 1200 / 800 / 1000

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

BPV 700, BRH 40 – surface-grinding machine width 400 - 700 × 2000 mm

SKQ 20 CNC - vertical lathe maximum turning ø of 2000, maximum L of 1200

Planers width 1600 - 3000 × 6000 mm

WHN 9, WHN 13 - horizontal boring machine width 2500 – 3500 × 900 – 2000 mm

SZ 1600 - portal grinder of slideways width 1600 × 6000 mm

WALDRICH - portal grinder of slideways width 1250 × 4000 mm

Schaudt microsa flexgrind M 200 VIB - universal centre grinder

ZEISS MMZ G 30 70 30 - universal 3D measuring instrument

Our objective is to supply fully machined cast pieces. We have our own machining shop equipped with the latest CNC technology, or we ensure subcontracting machining by our certified partners.

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Other services

METROLOGY— the control measuring centre is able

to provide complex services in the area of part inspections, utilizing progressive measuring methods on three-coordinate machines and other measuring devices designed for verifying geometric shape and position deviances

— a protocol on the inspected parts or a calibration protocol pursuant to the ISO standards can be prepared

MAIN MEASURING DEVICES:

KMZ – G 30 20 20 – MAUSER – 3D three-coordinate Zeiss measuring machine X / Y / Z = 3000 / 2000 / 2000, scanner head with 3D accuracy 3D = 4.5 + L/250 (μm)

ZEISS MMZ G 30 70 30 – universal 3D measuring instrument

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

TALYROND 2 HOBSON – roundness tester roundness measurements with an accuracy of 0.2 μm

MUK 300 – roundness tester

SIP 305 M – length measurements with an accuracy of 0.4 μm

ROUGHING SHOP AND PAINT SHOPDepending on the given customer requirements, we can rough the casting directly at the foundry and we can also apply a primer and/or final coat of paint.

FETTLING SHOP Blasting with the help of metal abrasives, grinding and final finishing of the casts.

— maximum capacity – 48 tons/day— blasting machines – Škoda, Schlick,

Spencer, PTB— direct and angular grinders,

mounted grinders

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TOOL SHOP— production of small and accurate

rotational and non-rotational parts in small series, including thermal processing

— vocational cooperation between the piece and small-series implementations (turning, milling, accurate drilling, round and flat grinding, grinding of threads and worms)

— special production— gear (direct and slanted wheals

for module 6), milled as well as ground

— shaped bevelled wheels— worms and worm wheels— production of inner grooves by

broaching, extruding and shaping— rolling outer threads— tip-free grinding of small parts— grinding wedge-shaped profiles

SHIPPING— packaging and storing casting

pursuant to given customer requirements

SHEET METAL PRODUCTION— complete production of bent and

welded pieces— laser burning using the TRUMATIC L

3030 machine— bending pieces on the LVD CNC press

brake (maximum length of 2.500 m)— welding and finishing operations— final coat of paint using RAL

hues pursuant to given customer requirements

HEAT PROCESSINGCHEMICAL AND HEAT PROCESSING:

— cementation in monocarb furnaces, furnace diameters 500 × 1.550 mm

— depth of the layer 0.1 to 1.5 mm— material refining, hardening in

chamber and shaft furnaces 800 × 600 × 1.200 mm, diameter of 700 × 2.300 mm

— annealing, tempering

HIGH-FREQUENCY HARDENING:

— shafts, slats, shims

MEDIUM-FREQUENCY HARDENING:

— maximum hardened diameter of 200 mm

— maximum length of the hardened part of 2,000 mm, weight of 200 kg

CHEMICAL SURFACE TREATMENT:

— mat chromium— hard chromium— blackening

— machine tools— gear manufacturers — agricultural machines— pumps, piping and fittings manufacturers— textile machines— automation and robot manufacturers

Industry and applications

Quality systemIn order to secure the required quality, a quality management and control system has been established at the foundry. It includes inspections of input raw materials and of the entire production process, and final inspections of the finished casts. The entire process complies with the quality management control standards pursuant to ISO. The foundry is the holder of the ISO 9001:2008

Lloyd's Register, BUREAU VERITAS and Germanischer Lloyd certificates. A part of the foundry is formed by a material laboratory and a sand laboratory, which are used for evaluating and long-term storage of records on chemical and physical characteristics of individual materials and forming mixtures, including spectral analyses and ultrasound tests.

— railway transport components— automotive industry— energy sector— shipbuilding industry— military industry

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Machine tools production program KOVOSVIT MAS MACHINING CENTERS

Vert

ical

MCV

Lin

e

MCV 754 ; 1016 QUICK MCV 750 MCV 1000 MCV 1270

Hor

izon

tal

MCH

Lin

e

MCH 500 MCH 630 MCH 800

Gan

try

MM

C Li

ne

MMC 1500

FIVE–AXIS & MULTI–TASKING MACHINES

Vert

ical

MCV

-MCU

Lin

e

MCV 1000 5AX MCU 700V[T]-5X MCU 1100V[T]-5X

Mul

tita

skin

g

MU

LTIC

UT

MULTICUT 500i MULTICUT 630

CNC LATHES

CNC

lath

es

SP L

ine

SP 280 SP 430 SPH 50

Uni

vers

al

cent

re la

thes

MA

STU

RN

Lin

e

MASTURN 550i MASTURN 820i

Spec

ial

tech

nolo

gies

RO

LLER

ROLLER 2800

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 519E: pzk@kovosvit.cz

www.masmachinetools.comhttp://references.kovosvit.cz

www.kovosvit.cz

Commercial representation

Sales director English and russian speaking customers

JAN KOČVARAM: +420 724 217 177 T: +420 381 632 504 E: kocvara@kovosvit.cz

Sales manager Czech speaking customers

OLGA ŤOUPALOVÁM: +420 602 578 227 T: +420 381 632 519 E: toupalova@kovosvit.cz

Sales manager German speaking customers

JAKUB RAKM: +420 721 068 461 T: +420 381 632 537 E: rak@kovosvit.cz