foamcast CASTING PROCESS jayshree machines & tools
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1 foamcast CASTING PROCESS
2 foamcast Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple patterns per cluster). 5. Coat cluster. 6. Dry coating. 7. Burn-off 8. Compact cluster in flask. 9. Pour metal. 10. Extract cluster from flask.
3 1. Mold foam pattern sections.
4 2. Age pattern to allow dimensional shrinkage. a. The foam material used to create the pattern shrinks in much the same manner as a typical casting. b. Patterns are aged by allowing them to rest at room temperature for a period of 5 to 7 days. c. Patterns may also be force aged in a drying oven to allow for quicker use.
5 Production patterns are assembled using a precision, automated gluing machine. Glue is printed to one section of the foam and then pressed against the adjoining piece. Multiple piece parts can be built up in this way and produce very complex geometry. 3. Assemble the Pattern
6 Glue individual patterns to sprue. Number of patterns per sprue is dependent on part size and/or configuration. Molded sprue is manufactured similar to foam pattern. 4. Clustering
7 Coating parameters are verified before coating cluster. Coating is mixed continuously to maintain properties. Cluster may be hand dipped or by automated robot station. 5. Coating
8 6. Drying & Burnoff Coating is dried in an oven at 120 oven at F( C) for 3 to 5 hours. Post Drying the Pattern is put in a Furnace for Burnoff
9 Cluster Shell is delivered to the Flask parked on the pouring line by conveyor or by hand. The Cluster is placed into flask and held in position by a fixture or by hand. If a Fixture is used it is timed to release the cluster during the compaction cycle. 7. Compaction
10 8. Metal Pouring Metal is poured to fill in the hollow shell. Metal may be poured by hand or with an automatic ladle.
11 9. Extraction Casting is allowed to cool in sand for a predetermined period. Sand in the Flask is then dumped on to a conveyor for recycling. Loose sand around the casting cluster helps protect the parts from damage.
12 Final Casting
13 Process & Cost of Production Comparison between Sand Casting and foamcast Process. Stage Process Description Sand Casting foamcast 1 PATTERN MAKING Required Manufacture of Tool 2 CORE BOX MAKING Required Not Required 3 PREPARING RISERS & RUNNERS Required Not Required 4 INSPECTION OF PATTERN Required Tool Inspection 5 PATTERN MOLDING Required EPS Pattern Molding 6 CORE MAKING Required Not Required 7 PAINTING Required Not Required 8 ASSEMBLY OF MOLD AND CORE Required Assembly of Risers 9 POURING Required Required 10 KNOCK OUT Required Not Required 11 REJECTION Around 10% 0% Rejection 12 SHOT BLASTING OF CASTING Required Not Required 13 RISER CUTTING Required Required 14 HEAT TREATMENT Required Required 15 SHOT BLASTING Required Required 16 FETTLING / FINISHING Required Cost 20% of Sand Casting 17 CASTING FINISH / QUALITY (VISUAL) Sand Casting Investment Casting 18 POST FINISH REJECTION Around 2% 0% Rejection 19 CHECK MAJOR SALVAGING Required Not Required
14 Process & Cost of Production Comparison between Sand Casting and foamcast Process. Stage Process Description Sand Casting foamcast 20 CHECK FOR MINOR SALVAGING Required Not Required 21 INSPECTION (DIMENTIONAL /NDT) Required Required 22 CHECK IF SALVAGING OF CASTING POSSIBLE Required Not Required 23 MACHINING Required Required 24 REJECTION POST MACHINING DUE TO DEFECTS 25 CHECK IF SALVAGING OF CASTING POSSIBLE Around 2% Required 0% Rejection Not Required 26 ASSEMBLY Required Required B. Cost Comparison: 1. From the above Table it is clear that foamcast reduces the number of process stages from 26 to just 12 stages. 2. The saving in these process stages is equivalent to savings of around 25% cost saving over sand casting process for as cast products & over 40% for machined components
15 Thank You for your valuable attention for more information on the process please don t hesitate to approach us at the counter or you can us your queries at casting@foamcast.in or contact us on
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