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Process
Description:
1) Engineering/Design
3D CAD data from the customer is utilized for
designing the tools and running casting simulations
with casting FEA software. Machine stock, gating
(rigging), and shrink compensation are added electronically
to the CAD during this tooling design phase.
2) Match Plates/Tooling
The match-plates begin as 3D CAD data that is
used to machine a master tool (match plate). Typically
the pattern is machined form a material specifically
designed for this purpose called “foundry board”
3) Molds (cope & drag)
Sand is mixed with the proper chemicals for binding.
Using a vibratory table to ensure optimal compaction,
the sand mixture is metered into the matchplates
where it is left to harden. The mold halves
(cope and drag) are then removed from the matchplates,
and assembled for metal pouring.
4) Metal Pouring:
Sand casting utilizes a gravity pour method of
filling the cavity. Several techniques are used
when pouring metal to ensure that a high quality
part is produced. Some of the variables that can
affect casting quality are metal temperature,
mold temperature, active chilling, mold tilt,
riser size/location, and metal filtering. To ensure
optimum metal quality Precise Cast uses certified
virgin metal, rotary degassing, and a continuous
melt furnace. Precise Cast’s metal pouring department
utilizes strict quality control of all materials
including multiple RATS (Reduced atmospheric testing
system) testing throughout the day. All data is
electronically documented and archived. Throughout
the process each mold and corresponding part made
is internally serialized and all known variables
are tracked and archived.
5) Shake Out/Clean Up
The sand is carefully removed to reveal the metal
casting. Remaining sand is removed via pressure
washing and the part is then cleaned and detailed.
During this process gates and risers are removed
and the part is prepped for machining.
6)Machining:
Final machining
is often used to create high-tolerance geometries
that are beyond the capabilities of the casting
process. Our machining centers are specifically
designed for the special requirements of prototype
and casting work. Each machine has 4th axis capability,
built-in CMM touch probes, and tool height sensing
probes to ensure consistent and accurate machining
of each casting.
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