600 Cannonball Lane O Fallon, MO Bruce Willson.
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1 600 Cannonball Lane O Fallon, MO Bruce Willson
2 Definition of an Engineer o Someone who knows almost everything o About almost nothing
3 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Availability Reliability Inventory Administrative costs Affordability
4 Premise: Castings present a cost effective solution for the manufacture of complex Near Net shapes that reduce Part Count and improve the affordability, manufacturability and reliability of the end product Successful casting design requires some specialized expertise and an appreciation for the strengths and weaknesses of the foundry process.
5 Provide an Overview of the Investment Casting Process Explore Investment Casting Strengths & Weaknesses Develop an Understanding of The Design Engineer s Role
6 Sand Casting Processes Green Sand Chemically Bonded Sand Gas Catalyzed / Coldbox Systems Shell Process Nobake / Airset Systems Unbonded Sand Lost Foam V-Process Permanent Mold Processes Die Casting Permanent Mold Casting (Gravity Diecasting) Low-Pressure / Vacuum Permanent Mold Casting Ceramic & Plaster Processes Investment Casting Ceramic Molding Plaster Molding
7 The Investment Casting Process is divided into two main branches which differ by their ceramic molding method. Solid Mold Process - Wax Pattern Assemblies are suspended within a casing which is filled with a ceramic investment. Once the investment is dry the Solid Mold may be fired and cast. The Solid Mold process was the prevalent Investment Casting method prior to the advent of the Shell Process in the 1970 s and remains in use today to manufacture castings of intricate detail Shell Process Wax Pattern Assemblies are repeatedly dipped into vats of ceramic slurry and sand to form a shell. The shell is then dried, fired & cast. The Shell Process and provides economies in material usage and eliminates the need for a casing.
8 Definition: Investment Casting is a foundry process by which a cast metal part is produced from a ceramic (investment) mold that has been formed by a disposable (wax or plastic) pattern. Investment Casting is sometimes also known as Lost Wax Casting or as Precision Casting. The American Foundry Society has identified 255 U.S. Investment Casting foundries.* AFS/MCDP Casting of the Year * Modern Casting January 2015
9 The Investment Casting Process
10 Eight basic steps to Manufacture an Investment Casting
11 Step 1: Produce a disposable (wax) pattern from mold
12 Step 2: Assemble multiple patterns to gating system Wax Pattern Assembly
13 Step 3: Form Ceramic Shell around Wax Assembly Layer of Ceramic Shell being applied by robot
14 Step 4: De-Wax Ceramic Shell Steam Boilerclave to de-wax shell
15 Step 5: Fire the Ceramic Shell Ceramic Shells being Fired
16 Step 6: Cast metal into fired Ceramic Shell Casting Ceramic Shell from Ladle
17 Step 7: Remove Ceramic Shell from solidified metal Removing Ceramic with Water Blast
18 Step 8: Separate Castings from runner system Gate Grinding Cut-off operation with band saw
19 With Aluminum castings there are additional operations:
20 Solution Anneal (T4) Anneal Oven & Quench Tank
21 Restore Straightness Straightening
22 Artificial Aging (T6) Heat Treat Oven
23 Final Inspection X-Ray Image (digital)
24 Eight basic steps to Manufacture an Investment Casting For the majority of process steps Investment Castings are handled as SPRUES and not as individual PARTS. Process is less sensitive to part configuration
25 Complexity at Incremental Cost Combine multiple pieces into one Reproduce fine detail Contours and rounded surfaces Undercuts Near Net Shape Minimize secondary operations Minimal stock allowance Design Freedom No draft angle Internal configuration Low Initial Investment Moderate tooling costs American Foundry Society 2013 Casting of the Year
26 Multiple Process Steps More Labor Intensive Process Higher per Unit Cost Long Cycle Time Approximately 3-weeks from pattern injection to shipping American Foundry Society 2013 Casting of the Year
27 Characteristics of Investment Casting
28 Alloy Machinability Near Net Shape Reduced Secondary Machining Eliminate Assembly & Fabrication Reduction of Part Count Light Weight Optimum wall Cosmetic Appearance RMS 2014 AFS/MCDP Casting of the Year - Honorable Mention Precision Tolerances ±.005 inch per inch
29 Electronic Boxes & Chassis o Part Count Reduction Fluid Flow o Near Net Shape Optics Housings o Thin wall to reduce weight Microwave Bends o Near Net Shape
30 Size of Part Determines the number of parts per sprue Configuration of Part Drives the number of gates Contributes to scrap & rework Inspection Requirements Radiography Physical Property Testing Premium Tolerances Can Increase labor content 2014 ICI Aerospace Casting of the Year
31 70 95% of total Product Cost is the result of Design Decisions.
32 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Manufactured with predictable yields?
33 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Availability Can the product be delivered when you need it?
34 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Availability Reliability Is the product Good when you receive it?
35 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Availability Reliability Inventory Did you receive all the needed parts for the assembly?
36 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Availability Reliability Inventory Administrative costs The costs of shortages & rejects?
37 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Availability Reliability Inventory Administrative costs Affordability Excess costs effect your price, profit and reputation.
38 The High Cost of Part Count o The fewer parts - the more Affordable an engineered Assembly
39 Castings, and in particular Investment Castings, are an effective method to reduce the total Part Count of an engineered assembly. Part Design Receiving Checking & Approval Incoming Inspection Document & Data Control Shipping & Receiving Make / Buy Decision Inventory Procurement Cost of Quality Requisitions Assembly Purchase Orders Risks of Assembly failure Expedites Warranty costs Surveillance Manufacturing Tooling Planning Inspection
40 AFS / MCDP 2013 Casting of the Year
41 Lightweight o 7.5 x 7.5 x 10 o 20 Ounces o.040 Wall Thickness o.060 Ribs for Stiffness
42 Lightweight o Lightening Pockets o Lightening Holes & Slots
43 Lightweight o Undercuts
44 Reduced Part Count o Mounting Bosses raised o Minimizes Secondary Machining
45 Reduced Part Count o Card Guide Slots
46 Reduced Part Count o Heat Sink Fins Includes Clearance for wrench access
47 Reduced Part Count o Pole Mount Clamp Half
48 Reduced Part Count o Superstructure
49 Reduced Part Count o (4) Mounting Hooks & Double D Holes
50 Lessons Learned
51 70 95% of total Product Cost is the result of Design Decisions. Manufacturability Availability Reliability Inventory Administrative costs Affordability
52 Castings are Custom Products o Have only one purpose for one customer o Require a Specialized Expertise Grow your Internal Specialized Expertise o Engineering o Quality o Procurement Develop Understanding of External Processes o Good Design Practices for each process o Strengths & Weaknesses of competing processes
53 Utilize good casting design practices o Adequate fillet radii o Reasonable tolerances o Datums & Datum Points Good Design improves casting Producability o Predictable casting yields o Stabilizes Price o Improves Delivery Performance o Consistent Product Quality Fewer rejections Fewer engineer changes
54 Design for Higher Levels of Complexity o o o o Complexity cost is largely reflected only in tooling & at pattern injection Part Count Reduction - Combine multiple piece structure Reduce secondary operations Reduce assembly operations Near-Net-Shape Design o Machine only Critical Features
55 Embrace Concurrent Engineering o Supplier Involvement early design Opportunity to combine parts and Reduce Part Count of Assemblies Avoid unnecessary Designed-In cost o Solicit design feedback from Supply Base Vendor & Industry Provided Educational Opportunities o Concurrent Engineering o IC-101 o IC-201
56 Thank You!
57 600 Cannonball Lane O Fallon, MO Tel: Fax: sales@ofalloncasting.com Web: YouTube:
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