Manufacturing a V-belt pulley – step by step

Moulds without model setup, assembling the model with a modular system on the moulding table

Manufacturing two mould halves

Adding the moulding sand, mixing with resin and hardener

Applying mould release agent to half of the mould to optimise the casting surface of the blank

Composite and clamped mould

Filling the mould with liquid iron at a temperature of approx. 1,300 °C

Cooling of the moulding boxes

Removing the watering boxes

Cast blank, already without sprues and risers, on its way to the blasting house

Pully after blasting, without any sand residue or scale adhering to it

Deburring the edges in the finishing department

Cleaning hard-to-reach areas with a compressed air chisel

Drehen der Innenkontur/ des Innendurchmesser

Pre-turning of the pulley, pre-drilling and grooving of the V-grooves

Drilling holes and cutting threads to accommodate the TaperLock bushing

V-belt pulley realigned with dial gauge and tapered bore introduced

Balancing in two planes, in accordance with quality grade G 6.3

Attaching counterweights, alternatively drilling opposite holes

Dimensional inspection of the V-belt pulley, tolerances in accordance with DIN 2211

Checking the conical bore with a gauge pin/calibre

Applying the primer with an electrostatic painting system

Application of wax, corrosion protection for machined surfaces

V-belt pulley sealed in shrink wrap – ready for transport