Technical Paper
Figure 6: Part #1, Consistent shell build and bridging resulting from closer automated part spacing
Figure 4: Part # 2 Example of automated assembly using common tooling
Figure 5: part # 1, 54 part tree showing bridging and shell reduction
molds for casting trials with 7, 8 and 9 parts per bar or 42, 48 and 54 parts per assembly. These additional parts would represent a potential increase in yield of 14 and 28% respectively over the original part layout of 42 parts per tree. Admittedly there was some skepticism over whether the denser assemblies would be able to be cast reliably. The new automated assemblies were run side by side through the foundry.
Initial
results looked promising as there were no visual defects after shell removal. As an extra precaution all parts were run through X-Ray to ensure there were no metallurgical defects such as internal porosity or shrink.
All X-Ray with zero defects.
completed we ran into our first road block.
was decided to only take advantage of the 8 parts per row or 48 parts per tree configuration in production. This is due to the fact that there is a weight limit on
28 ❘ January 2017 ®
Once the casting trials where Despite the positive results it
parts passed
Conclusion Automation reduces variability. When automation starts in the wax room the following benefits are achieved:
• Reduced shell material- the more parts you can put on an assembly the fewer assemblies you will need to dip resulting in reduced shell usage.
• Further shell reductions are produced based on reduced part spacing and bridging.
• Uniform part coverage
all downstream operations. The 54 part tree configuration exceeded this weight limit. Because of the unique End Of Arm Tooling (EOAT) design we are able to easily adjusted the number of parts per runner bar.
Figure 7: Part #1, 8 and 9 parts per weld casting examples
This allowed multiple
casting tests to be run optimizing the pattern spacing in the foundry without effecting the cycle time of the welding operation.
due to presentation of the part in to the slurry
• Increased accuracy of solidification models
• More accurate part cut resulting in reduced gate grind
• Reduced cut off scrap • Reduced scrap due to inclusions
These process gains allow your engineers to focus on corrective actions that focus on problems at the root of their origin.
All parts shown are thanks to Lamo- thermic in Brewster, NY.
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