and eventual shipment. This basic methodology keeps product moving through the metalcasting operations, though each department will require specialized configurations based on the building’s overall shape and size.
Melting Te melting department should
be located on an outside wall due to the high volume of metallic materi- als required for the melting process. Material handling in the melting department is important because it involves both newly acquired metal and returns from within the facility. Facilities that pour more than one
alloy at the same time have additional considerations because melting opera- tions will run side-by-side. Also, the method and location for metal returns to the melting departments need to be considered. Returns such as risers, sprues and pouring basins may occur at different locations throughout the cleaning process. Tese pick-up points must be incorporated into the material flow because they require transporta- tion back to the melting department. Te location of metal removal opera- tions should be as close to the melting department as possible to reduce the distance returns must travel. Minimizing the distance metal
travels from melting/holding units can reduce the required temperature of the metal tapped from the melt- ing/holding furnace. Long distances increase the metal’s temperature, leading to increased energy consump- tion and cost. Automatic pouring units, if pos-
sible, should be positioned to retrieve the metal directly from the holding/ melting furnace. If not, a heated trough can be used to transfer the metal to the pouring unit. Locations of the melt- ing/holding furnaces and automatic pouring are an important feature in the melting department layout.
Molding When making improvements to or
installing new molding equipment, four key features must be considered during initial planning and engineering: • Selection of a molding machine system.
Planning and engineering can improve material flow throughout the casting facility, no matter its size and complexity.
• Method of handling the molds away from the molding machine.
• Method of core delivery from the core machine to the mold.
• Location for setting cores in the molds. Different molding systems require
different handling methods. Establish- ing pouring as close as possible to the melting department should be a high priority in material handling, although it requires considerable planning to maximize efficiency. Matchplate jolt-squeeze machines
require either a pallet line or the use of a roller conveyor to move molds from the molding machines. Tese systems require the melting furnaces to be located at one side of the mold handling line so metal can be delivered and poured on the pallet line. Mold- ing/handling also may be located at the opposite end, away from the mold-
ing machines, so metal can be deliv- ered to the molds along each roller conveyor line. An automatic molding system
requires the melting department to be at the side near the molding machine to minimize the distance metal travels. A chemically bonded mold and core system requires the completed molds to be delivered to the melting depart- ment. Extra large molds, which are more difficult to transport, require a molding area adjacent to the melting/ holding furnaces.
Sand System Considerations for a casting facil-
ity’s sand system include available floor space, core and metal removal, shakeout, sand mulling and sand delivery. New sand storage hoppers should be located along an outside wall with the return hopper located as
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