Cambridge Brass finds perfect match with molding machine.

Cambridge Brass (a division of Masco Corp.), Cambridge, Ontario, Canada, has run a matchplate molding operation since 1905. In the past few years, the firm's waterworks valve business has been growing. However, this increased output and the need for higher casting tolerances started taking their toll on the metalcasting facility.

Cambridge initially addressed the problem by maximizing impressions on each matchplate, which over time resulted in all of its plates being reconfigured to maximum capacity. Although the firm addressed the issue of casting demand, the idea of maximizing impressions on the matchplate produced diminishing returns.

Cambridge knew a change from the traditional molding machine design was a necessity. As operations manager Ed Hesselink said, "We wanted a matchplate molding machine without draw guides and slippers." Cambridge considered the needs of several of its departments, compiling a list that identified key features required of a new machine:

* Foundry Management--decreased overall cycle times, faster throughput, increased productivity, maximized operational uptime and minimal scrap;

* Machining--greater machine precision, resulting in near-net shape castings to reduce machining costs;

* Pattern Shop--a problem-free acceptance of all existing mold patterns with minimal machine adjustments;

* Maintenance Dept.--less overall maintenance and easier machine installation and troubleshooting.

Cambridge began searching for a molding machine to suit its needs, but the task of finding something that fit the criteria wasn't easy. Visits to numerous metalcasting facilities were made before Cambridge discovered a high-performance matchplate molding machine being used in a facility that manufactured sprinkler heads.

Cambridge knew it had found the machine it needed to improve its business, and it found that Brock Solutions, Kitchener, Ontario, Canada, "was the only company that had it to offer." The machine's enhanced hydraulic controls allow for increased performance, while reducing cycle times and maintenance costs. The variable squeeze pressures allow for the production of harder molds. Fitted with automatic core setting, the high-performance machine reduces time to set cores, which paves the way for increased production.

The machine also incorporates new technology in the squeeze station to reduce mold shift. The shift reduction is achieved because of the machine's rigid squeeze station, draw guides with linear shafting and precision bushings, a rigid cope flask with an eject system and draw pins with replaceable seats. The tapered mold pins center the bottom board in the same location every time, eliminating board movement.

Other unique features include a hydraulically actuated bottom board feeder arm with proportional control and a bin gate operated by a single cylinder using extended force to close the gate.

Cambridge had found a high-performance machine that provided many benefits over its existing traditional machine. Mold shift was greatly reduced and more molds were produced while generating less scrap. The new high-performance machine provides higher uptime and accepts Cambridge's existing matchplate patterns. The new molding machine also required minimal adjustment and less maintenance.

Cambridge contracted Brock Solutions for design and implementation, and reports "outstanding performance improvements over the old equipment."

Select No. 001 at www.moderncasting.com/info