CASTING INNOVATIONS
Investment Caster Improves Throughput With Cleaning, Cutting Upgrades Designed Precision Castings (DP
Cast), Brampton, Ontario, Canada, having previously automated its shell department, identified a potential significant bottleneck in post-cast op- erations. Because of this, the steel and nonferrous investment casting facility approached Triplex Systems Inc., St Paul, Minn., a supplier of cleaning and cutting systems. To improve DP Cast’s capabilities in its cleaning department, Triplex Systems delivered its High- Pressure Waterjet Casting Cleaning Center and remote-controlled Gator Abrasive Wheel Cut-Off Machine. “We’ve been consistently upping our game to deliver a better overall customer experience by adding talent, streamlining our process through au- tomation, and seeking ways to improve efficiencies,” said Jan Holland, chair- man and CEO, DP Cast. “After doing the research, analysis and site visits, all roads led to Triplex Systems.” Before its investment in upgrad-
ing its cleaning capabilities, DP Cast relied on a manual system that limited throughput. Triplex Systems intro- duced the manufacturing concept of work cells to water-jet casting clean- ing and cut-off operations. Triplex provided the equipment layout for the work cell at DP Cast, including an overhead gantry crane for ease in moving invest- ment cast trees from cleaning directly to cut-off. “We introduced the com-
bination of automatic and manual cleaning in a single cleaning solution over 20 years ago,” said Joseph Tebbe, president, Triplex. “Often our Random Automatic Nozzle Movement Automation cleans 90% to 100% of most cast-tree configurations, but with more complex geom- etries, it’s also beneficial to have a manual cycle.” DP Cast had installed a
completely upgraded cleaning and finishing department that combined cleaning operations.
The casting cleaning center helped remove a potential bottleneck from DP Cast’s operations.
50 | MODERN CASTING August 2015
The Gator cut-off machine can be remotely controlled to improve worker safety.
Te turnkey waterjet system allowed DP Cast to improve efficiency and throughput while eliminating stress cracking, surface damage and the need for mechanical knockout or shot-blasting. Additionally, Te Model G20 Gator Abrasive Wheel Cut-Off Machine addressed the issue of safety in one of the more accident-prone
operations in a metalcasting facility. Using remote joystick controls, the operator can be at a distance during cutting, meaning it is not necessary for an employee to hold on to the tree or direct the cutting wheel by hand. “Safety has always been our first
priority,” said Tebbe. “And of course the customer benefit of this technol- ogy includes precise cutting, productivity and ergonomics.” Te Gator’s five-axis
abrasive wheel cut-off machine features a clamp that can hold castings by mimicking the motions required to cut gating. Te clamp can rotate manually 360 degrees via the ma- chine’s steering wheel and pivots 180 degrees to the left or right. Te abrasive wheel arbor raises and lowers for wheel height adjust- ment. Also, to increase accuracy, a laser guide line option can show the operator exactly where the cut will occur.
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