CUSTOMERS’ PROBLEMS
SOLVING
Several examples show how metalcasters collaborate with customers on design and process improvements.
U I
A MCDP STAFF REPORT
nfortunately in manufacturing, not every part is a straight- forward design with a straightforward method of produc- tion. When you need a component to reduce cost, provide critical properties or be delivered in an abbreviated time frame, working closely with your metalcasting supplier can yield solutions. Whether it is a conversion to casting from another
manufacturing process, a tweak to an initial casting design, or the use of alternative tooling methods, good metalcasting suppliers are often able to match the
your concerns with feasible solutions. Following are instances where
casting facilities stepped in to help a customer address and solve a problem through engineering, process control or new technologies to update decades- old patterns. T e metals, applications and casting processes may diff er, but what remains the same is the open customer-supplier partnership. ■
Weldment to Casting for Performance, Strength, Appearance
n 2013, agricultural tillage equipment manufacturer Wil- Rich, Wahpeton, N.D., ap- proached Monarch Industries
Ltd., Winnipeg, Manitoba, Canada, to explore converting a weldment to a ductile iron casting. T e component on the SoilPro 513 double disc ripper provides the main mounting structure for the shank assembly to be attached to the frame of the tillage unit. It also contains three of the major pivot points for the trip assembly. Originally constructed with eight steel pieces (torch cut and bent or saw
cut, then welded and machined), the component was diffi cult to manu- facture consistently and alignment remained a challenge. During welding, the supplier needed to rely on the fi x- ture to hold the pin holes in alignment, and Wil-Rich also had issues with the weld holding the bushings in place. T e casting conversion featured a single core in green sand. With an annual production volume of 2,000 pieces, the D64-45-12 ductile iron casting measures 22 x 12 x 10 in. (55.88 x 30.48 x 25.4 cm) and weighs 55 lbs. (25 kg). T e customer realized a
34 | METAL CASTING DESIGN & PURCHASING | Sept/Oct 2015
number of advantages, including: • T e machined casting provided
• By converting the component from a weldment, Wil-Rich freed up plant capacity in the welding and fabrication departments.
a 25% reduction in cost over the original weldment.
• T e machined casting, compared to the welded fabrication, resulted in much improved alignment in the holes with tighter hole-to-hole tolerances.
• T e cast component eliminated issues related to warpage and as-
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