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Foundry Automation

The document discusses mechanization and automation opportunities in the foundry industry. It outlines how foundries can automate processes like material handling, molding, melting and pouring to improve safety and productivity. Specific technologies mentioned include conveyors, continuous mixers, automated molding machines, and pouring systems. The document also discusses using robots for dangerous tasks and computer simulations to optimize casting design and foundry processes.

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aneesh19in
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4K views24 pages

Foundry Automation

The document discusses mechanization and automation opportunities in the foundry industry. It outlines how foundries can automate processes like material handling, molding, melting and pouring to improve safety and productivity. Specific technologies mentioned include conveyors, continuous mixers, automated molding machines, and pouring systems. The document also discusses using robots for dangerous tasks and computer simulations to optimize casting design and foundry processes.

Uploaded by

aneesh19in
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 24

Foundry Mechanization &

Automation
Aneesh Kumar. P
Roll No: 412114001

11/6/2014

Presentation overview
Introduction to Foundry & Casting
Limitations of foundry industry
Areas for mechanization &
automation
Robotic automation
Computer in foundry
Software packages for foundry
11/6/2014

Foundry & Casting


Afoundryis a factory that produces
metalcastings.
Casting is one of the most important and
major processes of manufacturing in
which shaped articles can be made in a
single step by pouring molten metal into
mould and allowing the melt to solidify
within it. The mould contains a cavity
(produced
by
the
pattern)
whose
geometry determines the exact shape of
the article or component.
11/6/2014

Main limitation to foundry


industry
The safety hazards to human
beings, especially when hot metal
and alloys are handled.
Produce
some
environmental
problems.

11/6/2014

Modernization, mechanization
automation Why?

To workers

Improved working condition


Ensure a safe , healthy and happy life

To owners

Higher productivity & Lower rejection


Improved Quality
Reduction in production cost
Better company image ,Stronger Partnerships &
improved marketing

Keep pace with the changing technology


11/6/2014

Areas for mechanization


and automation

Material handling
Handling of sand
Molding and Core making
Melting, Pouring and shakeout
operations
Control of dust and fumes
11/6/2014

Material handling
Invaluable asset in the rapid and
economic production of castings on a
large scale.
Efficient handling of items such as Sand, mould
castings

and

cores,

molten

metal,

Belt conveyors, Bucket elevator, apron conveyor,


Flight conveyor, Reciprocating and oscillating
conveyors, monorail conveyor, cranes.
Roller conveyor, pallet conveyor, overhead
conveyor, Industrial trucks, robots
11/6/2014

Material handling

Bucket elevator

Belt Conveyor

11/6/2014Roller Conveyor

Pneumatic Conveyor

Pallet Conveyor

Sand preparation and


control
Continuous Mixer
Moldability controller Slotted vibratory
feeder

Integrated systems
Sand preparation with mixed resin sand
continuously discharging into a molding
box placed on vibratory compaction table,
a pattern loop- mould stripping device
and a shake out with a reclamation plant.
11/6/2014

Sand preparation and


control

Continuous Mixer

Mobility Controller

Sand Preparation Mixer


11/6/2014

Mobile Mixer

10

Molding and Core- Making


Power operated molding machines
High pressure molding machines
Core blowing machine
Core drawing machines
Continuous core making machines

11/6/2014

11

Molding and Core- Making

Sand Molding Automated

11/6/2014

Automated Molding

Molding Machine

12

Melting, Pouring and


shakeout equipments
Machineries are deployed depends on factors
such as Type and condition of equipment
Economical feasibility
Availability of floor space

Automatic pouring system


Crane , lift truck, turnover truck, belt
conveyor
Vibrating type shake out, Bumber type shake
out
11/6/2014

13

Melting, Pouring and


shakeout equipments

Melt Shop

11/6/2014

Knockout Machine

14

Control of dust and fumes


Fine particles of saw dust in the pattern
shop
When sand is mixed and prepared during
molding, shakeout, feting operation
Fumes during melting, metal transfer,
pouring operation.
Cyclone, Filter, Electrostatic precipitator,
Mechanical collectors, Scrubbers, After
burners.
11/6/2014

15

Foundry process map


Sand (new/old), coal
dust, water, energy
Patterns, mold forms,
sand filling, coatings,
energy

Sand mixing
area

Dust, gases, noise,


reject mixed sand,
surplus sand

Molding
Molding Section
section

Dust, gases, surplus


sand, noise, rejected
molds

Casting area

Gases, organic
fumes

liquid metal

Energy

INPUTS

11/6/2014

Shake-out &
Cleaning area
Finished
products
16

Dust, gases, mold


forms, used sand

Non-Product
OUTPUTS

Control of dust and fumes

Dust Collector

11/6/2014

Working principle - Induced electrostatic charge

17

Robotic automation
Many operations that are performed
in a foundry are ideally suited for
robotic automation, because they are
Three Ds - dirty, dangerous and dull.
Three Hs
- hot, heavy and
hazardous.
Contd.
11/6/2014

18

Unimate
The first industrial robot
In
1954,
inventor
George
Devol
developed a machine , which he called
programmed article transfer and later it
was commercialized under the name of
Unimate.
Unimate was installed in a die casting
operation in 1961 at Ford Motor Company
and its main job was to unload hot
castings from the die-casting machine.
11/6/2014

19

Computers in foundries
Product design and Analysis
Transferring geometric information from
human mind to a computer
FEM (Simulation of Stress, Strain, Heat
transfer, Vibration, Fatigue, Fracture)
CAM (Simulate machining Operation,
Accurate and automatic calculation of
geometric properties)
Contd.
11/6/2014

20

Casting design and simulation


Convert part design to tooling design ,
showing orientation in the mould, parting
line, application of draft and allowances,
gating and feeding system, core boxes,
pattern plates and other elements
CastCHECK Based on numerical
simulation
Idea to make fast castability analysis
Design the complete casting system with
riser, sleeves, gates, chills, cores and moulds
11/6/2014

21

Software packages for


foundry use

Magmasoft Optimization of casting and foundry processes


CastCAE Mould filling and solidification simulation
AFS Solid 2000 Accurate prediction of shrinkage
porosity

NovaFlow and NovaSolid -

Mould filling and

solidification

ProCAST

Developed by UES Software

Using FE techniques with thermal calc database


Simulating solidification process

Mesh CAST Fully automatic 3D mesh generation


AutoCAST Knowledge based system for Cast design
decision, cast model creation and process simulation

11/6/2014

22

Intelligent Advisory Systems


Based on
Geometric reasoning
Involves understanding the part model and
recognizing the relevant features

Knowledge engineering
Involves storing and linking domain
knowledge with a computer program for
better decision support to the users

11/6/2014

23

Thank You

11/6/2014

24

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