Modern Casting January 2015

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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