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A


D


B


C


Fig. 1. These photos show the previous working conditions and setup of the cleaning and finishing department. A and C are the former arc/weld booths, B is the old grind booths and D shows the large floor grinding booths.


Te initial engineering design of


each weld/arc booth is shown in Fig. 2A, excluding the curtain enclosures that protect from arc and weld flash. Tis booth was fabricated primarily out of 12-gage sheet metal walls and hood. Te overhead covers on these booths are notched to allow the hoists to have space to safely maneuver cast- ings in and out of each work table. Te


Table 1. Abrasive Use Over Six Months Item


Type A Type B Type C


Total usage


Total lbs cleaned Lbs/Wheel


Item


Type A Type B Type C


Total usage


Total lbs cleaned Lbs/Wheel


Aug-12 1550 800 200


2,550


374,690 147


Jun-13 400 300 220 920


289,556 315


36 | MODERN CASTING January 2015


tables consist of steel castings, manu- factured in-house to be able to nest in each booth properly. Te air handler initially sat about 32 inches from the front of the table. Tese are rated at 4,500 CFM and can absorb a large amount of emissions and smoke. Tey have four fire-retardant cartridges with a manual air pulse cleaning system. An analysis of the initial prototype


Jul-12 900 600 560


2,060


319,166 155


May-2013 475 500 320


1,295


307,801 238


Jun-12 600 605 580


1,785


381,393 214


Apr-2013 400 325 220 945


267,815 283


May-12 900 750 460


2,110


342,602 162


Mar-2013 500 300 240


1,040


245,593 236


for the weld/arc booth quickly revealed all of the debris from the arc/welders was being drawn through the shield and into the filters, making them sus- ceptible to fire. Tis called for a buffer section of 36 inches, which was added between the work area and air handler. Te wall separating these were lou- vered to aid in deflecting sparks from entering the filter chamber. Lastly,


Apr-12 600 565 320


1,485


319,017 215


Feb-2013 525 550 300


1,375


324,176 236


Mar-12 950 750 720


2,420


407,724 168


Jan-2013 450 450 300


1,200


444,341 370


Total 5500 4070 2840


12,410


2,144,592 173


Total


2,750 2,425 1,600 6,775


1,879,282 277


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