close to the sand muller as possible, usually inside the building. Te sand cooler is located after shakeout, with the metal and core removal system prior to the sand cooler. After mull- ing, the sand is then transferred back to the molding machines. Green sand shakeout systems
require separation of sand and cores
from the castings and the elimination of core sand from the return sand. Chemically bonded molding systems may not require core sand separation, but metal must still be removed from the sand prior to reclamation, which will improve the quality of the sand returning to the muller. “Recent price increases for silica
sand have made reclamation sys- tems (both mechanical and thermal) financially viable for many medium and smaller sized casting operations,” Tinker said. “You want to close the loop as much as possible.” Many reclamation installations are
added to existing sand lines, which will lead to specific engineering consider- ations. Collaboration between engi- neers from the equipment manufacture and the metalcaster can help improve the material flow and handling of such add-on projects.
Core Production
Core production should be located near the molding area. Because core production rates rarely mirror mold production rates, storage space between the coremaking and molding departments must be allotted. While often unavoidable, the storage of cores can lead to a few problems: • Core scrap may increase due to the extra handling to and from storage.
• Cores in storage may collect moisture that could produce scrap castings.
• Storing cores ahead of molding operations can increase the dif- ficulty of tracking casting scrap. Production of cores at the same
rate as molds is the ideal solu- tion because it eliminates handling, reduces core and casting scrap, eliminates the need for storage and improves troubleshooting between coremaking and molding departments.
Casting Cooling Solidified castings must be cooled
before they enter the cleaning pro- cess. Te cycle time of the cooling process provides an opportunity to transport the casting a distance away from the mold shakeout area while it moves to post processing. This allows flexibility in the location of casting cleaning procedures, and may allow cleaning and finishing operations to be designed in a straight line for continuous casting flow. Te continuous flow of castings
Molds delivered via a rolling conveyor line can improve performance in melting/pouring procedures. 36 | MODERN CASTING October 2015
into the cleaning area also provides the opportunity for a continuous casting cooling process. Continuous opera- tions require the use of a vibrating
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