MOLDING
MOLDING PROJECTS ENGINEERING
Developed by:Helton Luciano Fogaça Weiss
Leonardo Semkiw Jr.
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 ContractionCalculation;
-Core Room Projects;-Solidification Simulation.
People in Charge of Engineering Projects Units
• Felipe Pacheco and John Schultz –
Under Order Unit and Special Alloys Units
• Fábio Mulhmann – Repetitive Unit
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.
Tools Used
» Software for designing 2D e 3D;
Solidification simulator software, Solidcast;
Tools Used
-Identifications;Element Setting . Funnel . Gates . Sleeves . Molds
- Filling;
- Hardening;
- Controls.
- Mold ejection;- Painting;- Drying; - Core Setting.
Molding Flowchart
Pattern Preparation Extraction/ Preparation
Closing/ Clamping
Cooling Shakeout
Pouring
-Core Manufacture
-Preparation /
Painting
Mold Manufacturing
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)
Pattern Preparation
Pattern: Lower Half
Core with structural reinforcement
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
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
Finishing
• Take away sharp edges;
• Drill the mold;
• In some cases nylon slugs are used.
Drilling Nylon Slugs
Painting
» Spraying
» Brushing
» Washing
» Immersion
Clamping/Core Setting
After drying the paint, the
cores are placed;
Taporil Setting and/or Glue
• The molds are cleaned with compressed air;
• Glue and/or Taporil is placed in order to seal the mold;
Closing
Box ClosingFlaskless Mold
Closing
Clamping
After closing the molds are clamped to resist the pressure of leaking .
Clamp Clamp and Weight
Screw Clamps
PIT
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
Red-hot Shakeout
Demolding
• 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
Core Room HV2- Isocure
Shell Core Room
Pepset Core Room
Under Order Core Room
Sand Laboratory
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).
Made to Measure Molding Molding Leaders: Carlos A . Bonetti
Márcio Theiss
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
Ingots
• The Made to Measure Molding is also responsible for the preparation of ingots
Produced Parts
Molding Carrousel- Repeats
Molding Leader: Valdenor Weyers
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
Parts Produced
Fast Loop Molding - Repeats
Molding Leader: Valdenor Weyers
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
Produced Parts
Shell Molding - Repeats
Molding Leader: Nazareno Pedrozo
• 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
Produced Parts
U.L.E. MoldingMolding Leader: Marcio Wiggers
• 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
Produced Parts
COPRAL
2006
Getting to know ALTONA’S processes