Simple Solutions That Work! Issue 13

2. TOOLING DESIGN Tooling design is a critical consideration for accurately filled and well-defined cores that can meet the casting process requirements. Tooling can be made from a variety of materials; from a wood and resin coated core box for low production, aluminum can be used in cold box, inorganic or no bake cores, to iron/steel boxes that are used in medium to high production core runs, or shell, hot or warm box considerations. Minimizing core defects and improving reliability begins with tooling design. The filling and curing analysis can be done with trial and error, plain old experience, or with commercial simulation software. Success at launching new tooling usually requires a combination of these steps. Tooling typically uses vents, which can be holes, screened, slotted, or other mesh-like materials that allow the air to escape during blow. Although critical to both parts, filling is the first most important requirement that must be established. Experienced tooling 5 Continued on next page DEFECT PREVENTION engineers will know where vents are needed. Rules of thumb are typically twice the vents in the cope than the drag in horizontally parted tooling scenarios. Never put a vent directly below a blow tube. Tool mounting and change out should be considered up front, especially with a new machine or a retrofit. Any quick-change mounting features (automatic or manually interfaced) need to be reliable, easily accessible, and safe. Considerations for cleaning, tool loading, gassing and exhaust connection, picker fingers adjustments, and loose piece connections are all important in the design and planning. Even the best designed tooling will need some periodic attention during production. Intermediate blowing off of the parting line, vent cleaning, or parting line spray are important. With any new core box, the core room operator must remember that patience and perseverance pay off in the end. Every core machine and tool has nuances that cannot be planned in advance. Just about every tool will require some modifications and only through patient trial and error will the tooling engineer be able to deliver consistent, high quality cores. 3. CORE MACHINE AND ANCILLARY SYSTEMS There are many core machine solutions to choose from; development or prototype machines, semi-automatic, to complete core machine cells using robotic handling systems. A first step to determine the proper core machine solution is to understand the size and complexity of the core. Larger cores can be lightened with mandrels or loose piece. One-piece cores are most desirable, however multi-piece cores may be required depending on the core complexity. Each machine must be considered for total cost of ownership, including a thorough review of initial capital