Determination of Bulk Dimensional Variation in Castings

Morse, Dr. James F. Cuttino Dr. Edward P.

UNC Charlotte (United States)

关键词: Molding;    36 Materials Science;    Variation;    Efficiency;    Manufacturing;   

RP-ID  :  NONE
RP-ID  :  FC36-02ID14231
RP-ID  :  838776

美国|英语

来源: UNT Digital Library

【 摘 要 】

The purpose of this work is to improve the efficiency of green sand foundries so that they may continue to compete as the most cost-effective method of fabrication while meeting tightening constraints on near-net shape manufacturing. In order to achieve this objective, the study is divided into two major components. The first component concentrated on identifying which processes control surface finish on the castings and which provide potential reductions in variations. The second component identified metrological methods that effectively discern between the geometry of bulk material versus surface finish in order to more accurately determine the quality of a part. The research resulted in the determination of an empirical relationship relating pouring parameters to dimensional variation, with an R2 value of greater than 0.79. A significant difference in variations obtained from vertical vs. horizontal molding machines was also noticed. When analyzed separately, however, the resulting empirical relationships for horizontal and vertical machines had reduced R2 values, probably due to the reduced data sets. Significant parameters when considering vertical and horizontal molding machines together included surface roughness, pattern type, iron type, pouring rate, copper content, amount of Western Bentonite, and permeability.