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