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“At Caterpillar, core [metalcasting]


expertise in the engine group is critical to our success,” Bevilacqua said.


Other Improvements First, it was “molding line 1.”


Cat Mapleton’s overhauled cope and drag line relies on one of the world’s largest robots.


alongside other casting sources. When the decision to build the


Technocast plant was made, it was clear that significant structural changes were needed to ensure Mapleton could continue to compete. Re-engineering the main molding line to be more flexible was just one step in a multi- generation transformation plan. Recasting the plant’s “key core” system (a coremaking process that utilizes a single core to lock together a larger package) was the next step. “We were making blocks on the key


core that were 10 to 18 liters, weigh- ing a maximum of 750 lbs.,” Bevilacqua said. “We needed to increase capacity on our large blocks (up to 9,000 lbs). As opposed to making a cope and drag, we make the new molds like a loaf of bread.” For about one quarter of the cost of


a new line, Mapleton transformed the equipment into an automated flask- less production line for large blocks. Remaining on the line are the sand


dispensing system, mold dip operation, drying oven and automated handling equipment. Individual cores in the old system weighed up to 200 lbs. Now, the cores can weigh up to 2,000 lbs. Te line makes coldbox cores for cylinder block mold segments and arranges them in a vertical orientation. Te heel segments for all the blocks are identical. Te middle segment design and number depends on the number of cylinders on the block (eight to 20). “We were trying to do things at the minimum investment,” Bevilacqua said. “A lot of the key core investments still had life to them.” Beginning in January 2010, the line


began production on gray and ductile iron blocks for Caterpillar’s 3500 and C175 platforms. In addition to the re-engineered key core line, Mapleton still has two manual molding areas for large blocks and miscellaneous large castings up to 25,000 lbs.


Ten, it was a “dead asset.” Now, the re-engineered cope and drag line is a key production asset in the Mapleton plant known as the “flex line.” One of the reasons the line is flexible is a new pouring system the plant has installed. Te spider-like contraption allows


Mapleton to pour molds at any height and with any iron it chooses, be it gray iron or ladle-treated ductile iron or CGI. Today, the once completely gray iron Mapleton plant pours 13% treated iron parts. “Te new pouring system offers a


3-ft. window heightwise,” said Gary McCoy, group manager for cylinder heads. “Te mold package can vary substantially, and we have the ability to put the pouring location anywhere in a cube that would be 3-ft. high by about the width of the flask by about half of the depth.” Mapleton’s CGI capabilities were


developed entirely in-house. Rather than use an outside firm to control its metallurgy, Mapleton relies on tight parameters in melting, treats the iron based on chemistry, performs a nonde- structive test on each ladle and pours only if the CGI quality is confirmed. “It is a ladle treatment process fundamentally developed in-house,” Bevilacqua said. “As with any CGI


This unique mold packaging system, in which segments of cores are sandwiched together, was developed by Cat Mapleton in-house.


June 2011 MODERN CASTING | 21


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