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