Molding presentation

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Molding presentation

  1. 1. MOLDING MOLDING PROJECTS ENGINEERING Developed by: Helton Luciano Fogaça Weiss Leonardo Semkiw Jr.
  2. 2. Engineering Projects Flowchart Making of the Foundry Project Making of Tooling (pattern + core box) Pattern Storage General Activities - ACVO´s; - Follow-up of Experiments; - Dimensional Evaluation; - FMEA´s; - Development of new Technology. . - Receiving Tooling; - CDM; -Storage; - Sub-contracted pattern shop; ; - Follow-up of Production. - Riser Calculation; - -Gates Calculation; Stock Allowance and Contraction Calculation; -Core Room Projects; -Solidification Simulation.
  3. 3. People in Charge of Engineering Projects Units <ul><li>Felipe Pacheco and John Schultz – </li></ul><ul><li>Under Order Unit and Special Alloys Units </li></ul><ul><li>Fábio Mulhmann – Repetitive Unit </li></ul>
  4. 4. Capacities <ul><li>Elaboration of foundry tooling design for common and special alloys in small,medium and large-scale parts; </li></ul><ul><li>Follow-up of making of tooling; </li></ul><ul><li>Receiving and storing of tooling; </li></ul><ul><li>Maintenace of patterns in use; </li></ul><ul><li>Check list and liberation of tooling for production. </li></ul>
  5. 5. Tools Used <ul><li>Software for designing 2D e 3D; </li></ul>
  6. 6. Solidification simulator software, Solidcast; Tools Used
  7. 7. Molding Flowchart <ul><li>Identifications; </li></ul><ul><li>Element Setting </li></ul><ul><li>. Funnel </li></ul><ul><li>. Gates </li></ul><ul><li>. Sleeves </li></ul><ul><li>. Molds </li></ul>- Filling; - Hardening; - Controls. - Mold ejection; - Painting; - Drying; - Core Setting. Pattern Preparation Extraction/ Preparation Closing/ Clamping Cooling Shakeout Pouring -Core Manufacture -Preparation / Painting Mold Manufacturing
  8. 8. Pattern Preparation In this stage the pattern undergoes a check list to be liberated and receives all the identification the part will contain. Pattern: Upper Half Pattern: Upper Half (Prepared)
  9. 9. Pattern Preparation Pattern: Lower Half Core with structural reinforcement
  10. 10. Molding The elements of the foundry design are put in place: gates, funnel, molds, feeders; The box is filled with a mixture of sand and resin. Filling / Compacting Facing with Cromite Sand
  11. 11. Stripping <ul><li>After the resins are hardened, the extraction of the pattern takes place,leaving the mold ready. </li></ul>Pattern with own frame: Flaskless Mold Pattern plated: Box
  12. 12. Finishing <ul><li>Take away sharp edges; </li></ul><ul><li>Drill the mold ; </li></ul><ul><li>In some cases nylon slugs are used. </li></ul>Drilling Nylon Slugs
  13. 13. Painting <ul><li>Spraying </li></ul><ul><li>Brushing </li></ul><ul><li>Washing </li></ul><ul><li>Immersion </li></ul>
  14. 14. Clamping/Core Setting After drying the paint, the cores are placed;
  15. 15. Taporil Setting and/or Glue <ul><li>The molds are cleaned with compressed air; </li></ul><ul><li>Glue and/or Taporil is placed in order to seal the mold; </li></ul>
  16. 16. Closing Box Closing Flaskless Mold Closing
  17. 17. Clamping After closing the molds are clamped to resist the pressure of leaking . Clamp Clamp and Weight Screw Clamps
  18. 18. PIT
  19. 19. Demolding <ul><ul><li>After pouring and cooling, the part is removed from the mold and the sand goes on for reclamation or is discarded; </li></ul></ul><ul><ul><li>The part makes its way to the Heat Treatment sector. </li></ul></ul>Cold Shakeout
  20. 20. Red-hot Shakeout Demolding
  21. 21. <ul><ul><ul><li>This is an important sector where the cores are made, prepared and painted; </li></ul></ul></ul><ul><ul><ul><li>The cores are also made from a mixture of sand and resin and this gives the form to the part’s cavaties, however complex they might be. </li></ul></ul></ul>Core Room
  22. 22. Core Room HV2- Isocure
  23. 23. Shell Core Room
  24. 24. Pepset Core Room
  25. 25. Under Order Core Room
  26. 26. Sand Laboratory
  27. 27. Controled Variables <ul><li>Resistance to cold tensile; </li></ul><ul><li>Granulometry; </li></ul><ul><li>Bench Life; </li></ul><ul><li>Permeability; </li></ul><ul><li>Acid Demand; </li></ul><ul><li>pH; </li></ul><ul><li>Iron Oxide Content; </li></ul><ul><li>Humidity; </li></ul><ul><li>Ignition Loss; </li></ul><ul><li>Resistance to hot tensile; </li></ul><ul><li>Solids Content; </li></ul><ul><li>Viscosity; </li></ul><ul><li>Hardness; </li></ul><ul><li>Fixing (paints). </li></ul>
  28. 28. Made to Measure Molding Molding Leaders: Carlos A . Bonetti Márcio Theiss
  29. 29. Capacity <ul><li>Equipment: </li></ul><ul><li>Cotinuous Mixer : Capacity; 30t/h </li></ul><ul><li>Lump Breaker : Capacity; 10 t/h </li></ul><ul><li>Parts </li></ul><ul><li>Weight-200 Kg - 8000 Kg ( geometry ) - ideal 450Kg / mold </li></ul><ul><li>Dimensions: </li></ul><ul><li>minimum - 400 mm x 400 mm x 200 mm </li></ul><ul><li>maximum - to 4000 mm of diameter </li></ul>
  30. 30. Ingots <ul><li>The Made to Measure Molding is also responsible for the preparation of ingots </li></ul>
  31. 31. Produced Parts
  32. 32. Molding Carrousel- Repeats Molding Leader: Valdenor Weyers
  33. 33. Capacity <ul><li>Equipment: </li></ul><ul><li>Continuous Mixer ; cap. 15 t/h; </li></ul><ul><li>Carrousel with 4 stations / 2 patterns of simultaneous parts; </li></ul><ul><li>Production cap.: 25 molds/hour; </li></ul><ul><li>Automated Pouring Line; </li></ul><ul><li>Demolder cap. 6 t/h; </li></ul><ul><li>Mec.System Sand Reclamation allows up to 95% of reclamation. </li></ul><ul><li>Parts </li></ul><ul><li>Ideal Weight: 50 Kg part/mold; </li></ul><ul><li>Maximum dimensions of flaskless mold: 640x800x340mm </li></ul>
  34. 34. Parts Produced
  35. 35. Fast Loop Molding - Repeats Molding Leader: Valdenor Weyers
  36. 36. Capacity <ul><li>Equipment: </li></ul><ul><li>Continuous Mixer :cap. 12 t/hour; </li></ul><ul><li>Production cap.: 18t part/day; </li></ul><ul><li>Demolder cap. : 6 t/hour; </li></ul><ul><li>Mechanical System of Sand Reclamation. </li></ul><ul><li>Parts </li></ul><ul><li>Weight: 40 Kg - 500 Kg - Ideal 200 Kg part/mold ; </li></ul><ul><li>Dimensions of flaskless mold: 1200x1400mm </li></ul>
  37. 37. Produced Parts
  38. 38. Shell Molding - Repeats Molding Leader: Nazareno Pedrozo
  39. 39. <ul><li>Equipment: </li></ul><ul><li>2 Automatic Machines; </li></ul><ul><li>Use of coated sand; </li></ul><ul><li>Production cap.: 17 molds/hour; </li></ul><ul><li>Cold and hot Clamping. </li></ul><ul><li>Parts </li></ul><ul><li>Weight: 0,5 Kg - 15 Kg - Ideal 8 Kg part/mold </li></ul><ul><li>Plate useful dimensions: 355x482mm </li></ul>Capacity
  40. 40. Produced Parts
  41. 41. U.L.E. Molding Molding Leader: Marcio Wiggers
  42. 42. <ul><li>Equipment: </li></ul><ul><li>Continuous Mixer with capacity of 1,8 ton/hour; </li></ul><ul><li>Production cap.: 35 molds/day; </li></ul><ul><li>Use of ceramic cores; </li></ul><ul><li>Use of pouring filters. </li></ul><ul><li>Parts </li></ul><ul><li>Weight : 1Kg - 250Kg - Ideal 40Kg part/mold </li></ul><ul><li>Plate useful dimensions: 500x500x650mm </li></ul>Capacity
  43. 43. Produced Parts
  44. 44. COPRAL 2006 Getting to know ALTONA’S processes

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