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Case history: casting firm saves weeks from model to mold.


Innovative Casting Technologies Inc. (ICT (1) (Information and Communications Technology) An umbrella term for the information technology field. See IT.

(2) (International Computers and Tabulators) See ICL.

1. (testing) ICT - In Circuit Test.
), Franklin, Ind., prides itself on its ability to accelerate its customers' product development cycles to reduce their time to market. It produces fast turnaround prototypes and low production castings in gray iron, ductile iron Ductile iron, also called ductile cast iron or nodular cast iron, is a type of cast iron invented in 1943 by Keith Millis[1]. While most varieties of cast iron are brittle, ductile iron is much more ductile, as the name implies.  and aluminum for customers such as Cummins, John Deem, Tecumseh, Caterpiller and Parker-Hannifin.

One of the tools ICT uses to achieve speed is CAD-CAM software from Delcam, Windsor, Ontario Windsor is the southernmost city in Canada and lies at the western end of the heavily populated Quebec City-Windsor Corridor. Windsor is located directly south of Detroit and is separated from that city by the Detroit River. The city has views of the Detroit skyline. , Canada, specifically PowerSHAPE and PowerMILL, which the firm uses to create models and secondary tooling in less than a day.

"For a customer who needed parts for an engine right away, we shipped five six-port exhaust manifolds This is a list of particular manifolds, by Wikipedia page. See also list of geometric topology topics. For categorical listings see and its subcategories. Generic families of manifolds
  • Euclidean space, Rn
  • n-sphere, S
 13 days after receiving the CAD file," said owner Jack Laugle, a second-generation patternmaker pat·tern·mak·er also pattern maker  
n.
One who makes patterns, as for sewing, carpentry, or industrial machinery.



pat
.

Once a pattern is designed, the company uses a series of machining centers to create patterns, coreboxes and finished, machined castings. Mills are used to machine the patterns, and machining centers are available for prototype machining. Castings and machining can be verified with a coordinated measuring machine, comparing the measured data to the CAD file.

"When we receive a pattern to work with, such as a bracket or manifold manifold

In mathematics, a topological space (see topology) with a family of local coordinate systems related to each other by certain classes of coordinate transformations. Manifolds occur in algebraic geometry, differential equations, and classical dynamics.
, we bring the customer's file into PowerSHAPE," said Tony Luenebrink, pattern designer. "We then easily break out the component parts, (cores, the outside shape and the coreboxes) in order to create a pattern we can use to produce the prototype parts."

PowerSHAPE's Smart Surfacing blends fillets and radiuses automatically, so that the choice of method for constructing a surface from a given set of lines, arcs or points is made automatically to give the smoothest surface. This saves hours of pattern design at ICT.

As information is added to the design, the software's selection is updated intuitively.

"Then, once the file is imported into PowerMILL, it is easy to program the machining in layers to suit the lengths of our cutters," Luenebrink said. "Many of our patterns can be 10-12 in. tall, and our cutters are 4-5 in. long, so programming in layers allows us to program the machine efficiently, avoiding cutting air."

Once a prototype casting is delivered and evaluated by the customer, its file can be changed and returned to ICT. "The Delcam software makes it easy to overlay (1) A preprinted, precut form placed over a screen, key or tablet for identification purposes. See keyboard template.

(2) A program segment called into memory when required.
 the 3-D model from the customer and see any changes in the new casting file we get back," Luenebrink said.

Patterns are machined in the ICT building and transferred to the metalcasting facility next door. Castings return to ICT for finish machining, painting and final shipment. According to according to
prep.
1. As stated or indicated by; on the authority of: according to historians.

2. In keeping with: according to instructions.

3.
 Laugle, production of the system can be up to 25 molds/hr., depending on the size and number of cores.

"With the patternmaking patternmaking

In materials processing, the first step in casting and molding processes, the making of an accurate model of the part, somewhat oversize to allow for shrinkage of the cast material as it cools.
, prototyping and casting capability, we can compress lead times and sell speed," Laugle said. "We are a 100% turnkey operation, which has permitted us to compress our lead times."

Visit www.delcam.com for more information.
COPYRIGHT 2007 American Foundry Society, Inc.
No portion of this article can be reproduced without the express written permission from the copyright holder.
Copyright 2007, Gale Group. All rights reserved. Gale Group is a Thomson Corporation Company.

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Title Annotation:PRODUCT INNOVATIONS
Publication:Modern Casting
Date:Jan 1, 2007
Words:476
Previous Article:Western Michigan--in November,Alfred Spada.(Chapter Newscast)
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