CASTING INNOVATIONS
Reducing Abrasive and Tool Costs In many metalcasting facili-
ties, the highest concentration of manual labor remains in cleaning and finishing operations, includ- ing removal of gating systems and parting lines and the cleaning of scales. Automation can reduce labor costs while improving overall operations. Additionally, Norton Abrasives, Worcester, Mass., a divi- sion of Saint-Gobain, Paris, offers solutions for metalcasting facilities to reduce costs associated with cutting tools and abrasives in fully and partially automated cleaning and finishing operations. Depending on a metalcaster’s specific needs, automation offers a
• Improved Environmental Health and Safety—Creating distance between the grinding media and the operator decreases the risk of injury and alleviates other safety concerns. It also reduces costs associated with Personal Protection Equipment (PPE) that are otherwise necessary in a manual environment.
• Improved Quality—Automation creates repeatability and process control, which can reduce scrap.
• Decreased Cycle Time—Automation
One facility saved more than $100,000 with the installation of a single robotic finishing cell.
variety of benefits, including: • Labor Costs—Automation allows efficiencies that reduce manual labor.
• Advanced Abrasives—Robots and grinding assisted systems (i.e., swing frame grinders) allow for the utiliza- tion of more durable and aggressive abrasive products by removing con- straints such as operator fatigue and manual limitations of grinding forces.
greatly reduces the limitations of manual cutting, grinding and clean- ing including increase cycle times.
• Yield—In the case of high material costs (i.e. high nickel and cobalt- chrome alloys), controlling yield can lead to substantial savings by reduc- ing kerf loss. Savings in a metalcasting facil-
ity’s automated cleaning and finishing operations can continue beyond the
initial procurement of equipment. Norton Abrasives works closely with customers and OEMs to develop optimized solutions for cleaning and finishing needs that reduce abrasive and cutting tool costs linked to automation. Te two main things to consider when engineering an abrasive prod- uct are cut rate, or material removal rate, and life, or wheel wear rate. Because robotic operation param- eters differ from manual, automated operations may require different abrasive solutions. For example, a robot will be less sensitive to grinding pressures and
vibration than a human operator, so a harder, longer lasting wheel could sig- nificantly reduce costs related to abra- sive consumption. Additionally, a cutoff robot will be capable of applying higher cutting forces with a more aggressive abrasive product, which could increase material removal rates and throughput. An engineered abrasive product can achieve ideal material removal rates and optimize life. A recent metalcasting facility’s con-
version from manual to machine grind- ing highlights the advantages found in automation. Te facility installed automated grinders for finishing ductile iron tractor components. Five operators requiring full head
gear with oxygen and a leather apron were needed to finish a single part in the manual grinding station, while the robotic cell required just two operators (without PPE requirements). Te cycle time dropped from an average of 65 minutes per part to just 24 minutes, a decrease of 63%. By minimizing labor costs and abrasive consumption, the fa- cility decreased its annual costs by 66%, saving more than $100,000 with the implementation of a single robotic cell. Automation can limit labor costs,
decrease cycle times and improve yield, quality and safety. Additionally, robots and grinding assisted systems allow for the utilization of more durable abrasive products versus manual grinding opera- tions that are limited by and operator
Automating cleaning and finishing operations can boost efficiency and reduce labor costs.
force and fatigue. Visit
www.nortonabrasives.com for more information.
January 2014 MODERN CASTING | 59
Photos courtesy Vulcan Engineering.
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