Automation, whether in molding or another department, can help streamline material flow through the casting facility.
pan conveyor or an overhead chain conveyor to deliver the castings to the first cleaning station. Because the location for start- ing the cooling cycle for castings is flexible, the design can be based on a number of factors: • The removal of metal from the casting creates a considerable amount of material to return to the melting area, so placing the cooling system near the melting depart- ment will reduce material handling and distance.
• Automatic return systems can reduce material handling consid- erations and minimizes con- tamination and mixing of metals being charged.
• The pick-up points and delivery to a designated bin in the metal stor- age area can be cost effective and improve the plant environment.
Casting Cleaning At the completion of the cooling
cycle, the casting’s metal determines the first operation in the cleaning pro-
cess, whether that is shakeout, cut-off or knockout operations. The next operation is shot-
blasting, with the exception of aluminum castings, which are normally shotblasted at the end of the cleaning process. Continuous shot-blasting reduces manpower necessary for loading and unload- ing, while batch shotblasting may increase handling due to the ebb and flow of prepared castings. Grinding may be done with a
variety of tools, including stand grinders, belt sanders and chipping tools. From this point, many cast- ings will require heat treatment, reblasting and inspection before being ready for shipping.
Overall Improvements
Te metalcasting facility with ideal material flow and handling may not exist, but company executives are becoming more receptive to improved efficiency in an effort to reduce costs and improve performance. “We’ve seen a definite shift
toward efficiencies, both in produc- tion and operational equipment,” Tinker said. “We’ve seen [metalcast- ers] analyzing utility consumption, to where it’s a crucial part of their economic decision-making.” Early planning provides the time to design an efficient flow program that reduces handling inefficiencies. Te results of an effective continuous material flow include: • Reduced material and casting handling.
• Reduced manufacturing time. • Reduced inventories. • Reduced delivery times. • Improved customer relations and satisfaction.
• Reduced scrap. • Improved casting quality. • Cleaner work environments. • Improved employee relations and satisfaction. If a metalcasting facility can
successfully implement equipment improvements and installations, the metalcaster can expect real, tangible benefits.
October 2015 MODERN CASTING | 37
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68