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Foundrymen Focus on Ways to Improve Production at Regional.

With the theme of "Casting: A Process for the New Millennium," the 49th annual AFS A distributed file system for large, widely dispersed Unix and Windows networks from Transarc Corporation, now part of IBM. It is noted for its ease of administration and expandability and stems from Carnegie-Mellon's Andrew File System.

AFS - Andrew File System
 Northwest Regional Conference held March 9-11 in Tacoma, Washington, provided a chance for foundrymen to see and hear about some of the opportunities available to improve casting production in the 21st century.

During the 19 technical presentations given by foundrymen, suppliers and casting end-users, attendees were presented with new ideas "New Ideas" is the debut single by Scottish New Wave/Indie Rock act The Dykeenies. It was first released as a Double A-side with "Will It Happen Tonight?" on July 17, 2006. The band also recorded a video for the track.  relating to relating to relate prepconcernant

relating to relate prepbezüglich +gen, mit Bezug auf +acc 
 solidification modeling, 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.
, computerized melt and sand systems, and the increasing expectations of casting customers. The 3-day supplier exhibition that featured more than 40 companies allowed attendees to peruse pe·ruse  
tr.v. pe·rused, pe·rus·ing, pe·rus·es
To read or examine, typically with great care.

[Middle English perusen, to use up : Latin per-, per-
 some of the newest innovations in metalcasting technology. Attendees also had the opportunity to visit local plants including Thomas Machine & Foundry, Marysville, Washington Marysville is a city in Snohomish County, Washington, USA. The population was 25,315 at the 2000 census. Marysville is known as "The Strawberry City" due to the large number of strawberry farms that once surrounded the city in its earlier days. , Western Steel and NorthStar Casteel, Seattle, which all had undergone recent modernizations and expansions.

Foundry Modernization

In one of the conference's panel presentations titled "Automation for the New Millenium," Cameron Girton, Spokane Steel, Tom Lochman, Romac Industries, Bill Gibb, NorthStar Casteel, and Robert Alexander

For other people named Robert Alexander, see Robert Alexander (disambiguation).
Robert Alexander (c.1740-1805) was an American planter, lawyer, and Tory political leader during the American Revolution.
, Western Steel, spoke about recent modernization projects at their foundries.

Girton's presentation focused on his plant's installation of a new flaskless nobake molding and pouring system for casting high- and low-alloy steel. Due to an increase in the size of components for its military, transportation and rock-crushing industry customers, the foundry was forced to shift from green sand to nobake molding.

During planning for the modernization in 1997, Spokane Steel visited six local foundries to develop an understanding of all the variables that must be addressed in the start-up of a nobake line. The variables Spokane identified were: pattern staging, fast-loop molding, coating, coresetting, automatic closing, pouring and cooling, shakeout Shakeout

A situation in which many investors exit their positions, often at a loss, because of uncertainty or recent bad news circulating around a particular security or industry.

During the dotcom boom and bust, numerous shakeouts occurred.
 and sand reclamation, material handling and throughput, a management control system, and system diagnostics.

The result for Spokane Steel was a flaskless system that handles mold dimensions from 32 x 38 x 8/8 in. to 48 x 84 x 23/23 in. The system has a production rate of 10 molds/hr for its maximum size molds and 20 molds/hr for its minimum size molds. The footprint for the system is 18,000 sq ft, and it requires six workers to operate.

"Most nobake systems have mold staging areas staging area
A place where troops or equipment in transit are assembled and processed, as before a military operation.

Noun 1.
 to build up molds for pouring," said Girton. "In this system, we have a 3-min cycle for molds."

Lochman discussed his foundry's upgrade to vertically parted high-production molding. In 1993, Romac's 5-year sales forecast Sales forecast

A key input to a firm's financial planning process. External sales forecasts are based on historical experience, statistical analysis, and consideration of various macroeconomic factors.
 projected a 70% increase in demand for cast iron couplings and fittings by its main customer, the waterworks waterworks: see water supply.  industry. To meet this demand, it needed to expand its operation. In an engineering study, the foundry compared the advantages and disadvantages of adding two horizontal molding lines vs. adding a vertically parted molding line to the operation.

After examining sand delivery, melt rate, metal delivery, pouring, training, patterns, workers and a host of other factors, the foundry decided to add vertically parted molding. As a result, it required a new sand system (100 tons/hr with temperature control), two furnaces (one to hold and pour and one to melt) and a shakeout system. Initially, the foundry decided to manually pour this new high-production line. However, after experiencing consistency problems with the pours as well as metal delivery problems, the foundry switched to automatic pouring.

The keys to the foundry's start-up of the new system were the up-front planning and extensive employee training. In addition, the foundry purchased top-quality tooling for the new molding line that paid for itself in reduced finishing costs.

The third presentation on the panel by Gibb discussed NorthStar Steel's development of work cells in its cleaning and finishing operation to eliminate the bottleneck that had developed over the years.

The first step was to increase the space for the department from 40 x 60 ft to 120 x 100 ft. Then, the foundry eliminated its previous method of casting transport using forklifts and metal bins and added a conveyor system. Each worker then was given his own workstation with all the tools he needed to weld, grind or perform other finishing duties. Each cell also was equipped with the proper environmental equipment to improve air quality as well as ergonomics ergonomics, the engineering science concerned with the physical and psychological relationship between machines and the people who use them. The ergonomicist takes an empirical approach to the study of human-machine interactions. . These cells then were connected via a conveyor system. The result for NorthStar was improved flexibility for the workers and increased productivity.

The last presentation for the panel was Alexander's discussion on Western Steel's installation of a sand reclamation system. In 1998, the foundry installed a rotary reclamation system with a fluid bed classifier for its silica and zircon zircon

Silicate mineral, zirconium silicate, ZrSiO4, the principal source of zirconium. Zircon is widespread as an accessory mineral in acid igneous rocks; it also occurs in metamorphic rocks and, fairly often, in detrital deposits.
 sand. The reclamation system has a throughput of 3.3 tons/hr and the foundry passes its sand through the system four times before reusing it.

The new system required an investment of $390,000. However, from 1998-99, the foundry saved $132,000 in new sand purchases.
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Comment:Foundrymen Focus on Ways to Improve Production at Regional.
Author:Spada, Alfred T.
Publication:Modern Casting
Article Type:Brief Article
Geographic Code:1USA
Date:Jun 1, 2000
Previous Article:Demand Contraction to Continue.
Next Article:Regional Speakers Discuss Metalcasting Education, Melt Basics.

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