The casting conversion was an integral component in an adjustable pitch mine ventilation fan. T e fan manufacturer partnered
with Pier Foundry & Pattern Shop, St. Paul, Minn., to supply what would become a one-piece ductile iron casting. After a six-month collabora- tive eff ort that included a number of design iterations and simulations, the metalcaster delivered sound castings via its green sand molding line that led to signifi cant benefi ts for the customer. T e casting conversion reduced costs by more than 30%, saving the cus- tomer a projected $41,000 in the fi rst full year of production. Additionally, the fan supplier has
increased shop capacity because the castings are delivered ready for assem-
“
bly, allowing sawing, machining and welding resources to be used for other assemblies. Since the successful col- laboration on this fi rst mining hub, Pier and its customer have begun exploring conversion possibilities in other size ventilation units, and the two expect to increase collaboration in the future.
Casting Crash Course
Although the fan manufacturer’s engineers knew the complex weld- ment was a good candidate to be converted to a casting, Pier Foundry faced a challenge in educating them about design considerations unique to metal castings.
When converting to a casting, you are starting with a clean slate. You don’t necessarily want to recreate the weldment.” —DUANE RICE
“T ey are not buying a stock item
off a shelf,” said said Duane Rice, sales specialist, Pier Foundry. “T ere is a well-defi ned process from design through production and delivery. We need to understand their design intent and what’s critical to them, so we can provide the best product at the lowest price. When converting to a casting, you are starting with a clean slate. You don’t necessarily want to recreate the weldment.” To ease collaboration between the
two design teams, Pier Foundry start- ed off with a “Casting 101” course for the customer’s mechanical engineer. “T e company was relatively new to
castings,” said John Dulaney, sales and engineering manager, Pier Foundry. “T ey virtually had no experience with what it takes to make a good casting: fi llets, feed paths, draft—all of those considerations. Once they got through a bit of initial instruction, their designer provided the fi rst version of what they would need to meet fi t, form and function.” T ough relatively new to metal cast-
Jul/Aug 2014 | METAL CASTING DESIGN & PURCHASING | 37
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