“Te essence of the whole manufacturing process is automation,
like cold flow, flaking and porosity in the center journals before the casting is placed on an automatic work-in- process conveyor system that holds 2,400 castings, or approximately two and a half days’ production.” Te castings enter a stainless steel shot-blasting unit to achieve Volk- swagen-specified surface finish on the casting face. From there, they enter the machining cell, which is housed in a facility where machining and dimen- sional inspection is conducted in a con- trolled atmosphere with positive pressure for temperature stability. Te castings are fed into three identi-
cal double-pallet horizontal machining centers. Each machine performs the same operations, such as facing and machining of the oil channels, before a robot turns the casting around in a horizontal orientation for machining of the chain and exhaust sides. Like the casting cell, the robot is
centrally situated and moves the castings when an operation or cycle is completed. Synchronization with the machining
traceability and quality control.” —Graham Hardisty
centers is all pre-programmed, ensur- ing optimal process performance. After this initial machining, the castings are transferred to a CNC machine that does a rough boring and measuring before completing a fine bore. Full statistical process controls are
carried out in-line throughout the machining process. If dimensions extend beyond tolerances, the machine will stop automatically for potential tool change. Another robot then transfers the cast- ings to a CNC brushing machine that deburrs the machined faces to a specified roughness. From there, the castings are conveyed to a washing machine. An in-line automatic inspection
system carries out three different checks, ensuring every casting under- goes tests for dimensional cam bores,
high pressure oil gallery and cavity pressure. Castings are moved via a gantry system. Again, parameters have been pre-programmed to allow for rejected components to be conveyed to a holding area where management can take corrective action. If all three tests are passed, the casting
goes for a second visual inspection and is sent for packing. Each container has full traceability so one can be identified easily if it needs to be quarantined. “Tis project has shown that Zeal- ous has become a strategic partner with a major OEM,” Reid said. “Te facility that we have installed is world class and able to manufacture complex components. Tere is no reason why we can’t extend our participation in similar projects in the future.”
September 2013 MODERN CASTING | 23
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