Metalcasters can automate pouring and molten metal transfer in a variety of ways, including using a programmed robot, as in this investment casting facility.
it and using in the wrong areas,” said Robert Conrad, vice president foundry sales, Roberts Sinto Corp., Lansing, Mich. “Autogrinding and autopouring takes operators to a safe place, and they give repeatability for part quality.” Increasing standards demanded by customers are driving all metalcasters
to incorporate more control in the process, which could include pouring. “Simple castings are being made
offshore. More sophisticated castings are made here,” said Patrick Brown, vice president, Stotek Inc., Pewaukee, Wis. “Tat is driving the requirement to autopour.” Metalcasting facilities have a
wide variety of automated molten metal transfer methods to choose from depending on their existing production layout and equipment. Tese methods are either heated or unheated systems, meaning the molten metal is held either at a set temperature from furnace to the mold or it loses heat in the transfer process.
CASE FILE: OPTIMIZING POURING AT NOVOCAST
Producing cast components from 1 lb. to 200 lbs. includ- ing axle carriers, differential cases and turbo housings, Grede Holdings’ Novocast, Nuevo Leon, Mexico, was approaching full capacity and wanted to boost production. Its pouring operation wasn’t causing a bottleneck at the time, but it was an area where increased efficiency would reduce downtime to allow for a 15% increase in molding production.
In 2013, as an upgrade to its existing pouring robots, the facility pursued the installation of a pressure pour system that would boost production by 10,000 metric tons a year to accommodate increased customer demand. “You should be limited in production by the most costly part of your operation,” said Raul Lopez, managing director of Grede Holdings’ two Mexican facilities, in reference to the melting area. “Basically, we wanted to maximize the capabilities of our melting and pouring departments so we can fill molds more quickly.”
34 | MODERN CASTING February 2015
Novocast invested approximately $2 million into the pres- sure pour system, a modest sum when compared to other, more comprehensive facility improvements. “Considering we could increase capacity by 10-15%, we thought it was a great idea,” Lopez said.
The logistical complications of installing one pouring system while another operates at full capacity proved to be the biggest challenge for Novocast’s team of engineers. The most crucial step occurred in December 2013, when much of the new system was installed during a routine 10-day maintenance shutdown.
Now the pressure pour system is handling the large majority of Novocast’s production while the old system, which transferred metal from the melting area to two robotic pouring stations via ladles, continues to handle certain components. With the boost in pouring efficiency, Novocast has increased mold filling speeds from 180 molds per hour to nearly 200.
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