Wavertree Pillar PalmPresented By:
The University of Wisconsin PlattevilleSenior Design
The Design
Solidworks drawing of cast part after adding the parting line modifications to the bottom cylinder
The Design
Solidworks drawing of final product after all steps completed
Rivet Holes
Chamfer&
Step
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Pattern Design
• Mastercam drawing of pattern assembly
• Core (lower half), Pattern (upper half)
Core
Pattern
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Tool Path for Machining
Tool paths for final machining of part
Tool paths for machining cope half
of pattern
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Tool Path for Machining
Start of machining program for cope of pattern as shown in
Mastercam
End of machining program for cope of pattern as shown in
Mastercam
Solidification Modeling(MagmaSoft Program)
Video of Solidification in
MagmaSoft
Niyama criterion in MagmaSoft
Solidification Modeling(MagmaSoft Program)
Video of mold being filled using Magma
Machining Pattern
Machining program for location holes
as shown on the 2-axis CNC mill
Machining program ½ done for cope of pattern as shown on the 4-axis CNC
mill
Machining Pattern
Program near finished for cope of pattern on 4-axis
CNC mill
Cope of pattern finished on 4-axis
CNC mill
Machining Pillar Palm
Fixture for machining step on
bottom of part.
Fixture for machining step on bottom of part with
part on it.
Drilling Rivet Holes
Fixture for machining holes in
palm with part being machined
½” endmill milling holes after drilling
operation
Machining Chamfer and Step
Chamfer on bottom of part being
machined
Step on bottom of part being machined
Project Photos
Gating and Riser Design
Foseco Riser
Pillar Palms
Gating
Gating and Riser (Cross Section)
Pillar Palms
Foseco Riser
Gating
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Solidification Modeling(Solidcast Program)
Shows how casting solidifies after pour
A27 Steel Chemical Composition
• Required 5 test pours to obtain correct composition–5 test heats = 663 pounds of steel
• 14 Heats total = 1848 lbs melted• Composition
–Equivalent to Mild Steel• 0.192% Carbon (C)• 0.974% Manganese (Mn)• 0.794% Silicon (Si)
Personal Protective Equipment
• Hard hat with shield• Safety glasses• Aluminized jacket• Aluminized apron• Aluminized spats (cover legs and ankles)• Aluminized gloves • Steel toed shoes
PPE Required For Grinding
• Hard hat with shield• Ear plugs• Safety glasses• Flame resistant jacket
• Steel toed shoes
Coordinate Measurement Machine
• Inspected prototype• Made positioning fixture• Visited “Stainless Foundry and
Engineering” for consulting• Measured each
casting for tolerances
Coordinate Measurement Machine
• Centerline – center hole to center hole
• Distance betweenhole and centerline
• Degree of anglefrom center ofhole to centerline
Measurement Points
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Tensile Bar Testing• Made keel blocks• Machined tensile bars• Pulled tensile bars tests
–Tensile strength–Yield strength–Elongation
• Results–All parts met specification
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Donations Make the Difference
Cost: Purchased vs. Donated
71%
29%
Donated Purchased
Without donations this project would not be possible
Thank You to our Donating Companies
J. B. DeVENNE
Project Photos
Overhead Costs• Sand mixer and self centering vice• Increased mold making and machining efficiency
• Sand mixer - $30,000• Vice – complete donation
Overhead CostsItem Cost
Sand Mixer $ 8,000.00 Self Centering Vice $ 2,733.00
Grand Total $ 10,733.00
The Breakdown
Cost Per Unit (Sand Mixer, Labor, Vice included)Cost Totals
Donated $ 4,355.15
Purchased $ 1,755.81
Labor $ 68,600.00
Sand Mixer $ 8,000.00
Grand Total $ 82,710.96
Cost Per Part $ 2,067.77
All costs included
• No sand mixer, vice or labor included in total cost–Platteville students are free labor
The Breakdown
Cost Per Unit (No Labor Included)Cost Totals
Donated $ 4,355.15
Purchased $ 1,755.81
Grand Total $ 6,110.96
Cost Per Part $ 152.77
Project Photos
Facts and Figures• Resources Consumed• 8000 pounds of sand• 1800 pounds of slitter scrap (steel)
• Over 2500 man hours• $1800 in purchased goods• $4400 donated by outside
firms
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Project Photos
Project Photos
Thank You• Dr. Kyle Metzloff Ph D.
–IS 4610 Professor• Ray Monroe
– Steel Founders Society (SFSA)• Philip Harrison
– Penumbra Design• Benji Johnson
–Magma Soft• Greg Gauerke
–Perfect Pattern – Core Box Build• Scott Sharpee
–Neenah Foundry
The University of Wisconsin Platteville
Thanks you for your support