Simple Solutions That Work! Issue 13

Contact: JERRY SENK j_senk@emi-inc.com 7 Modern core machines are routinely supplied with a full enclosure, fast acting containment windows, and automatic high- pressure tool cleaning functionality. The automatic tool cleaning function adds an additional level of safety by keeping the operator away from the automatic movements of the core machine. A properly ventilated enclosure will help improve the core room environmental conditions by minimizing catalyst (amine, methyl formate, SO2, and CO2). It is equally important to conduct routine cleaning of the core machine itself. The sand magazine, inlet hoppers, slide gates or butterfly valves should be cleaned at the end of each shift. Blow and exhaust screens will require some preventative maintenance to keep them in good operating order. Seals on the tables, gas plates and blow plate sealing surfaces should be routinely inspected and replaced. Even the machines alignment of pins, bushings or other locating features needs routine inspection and adjustment. Excess sand build-up around the moving parts of the core machine will cause process and operational errors that can affect the quality of core, and lead to premature wear of guide rods, rollers and bushings. Some core processes may even require frequent cleaning throughout each shift, such as loose piece slides. In these cases, it’s helpful to record the number of cycles between cleaning and create some process steps that consider what cleaning steps may be required. This data can be made part of any receipt function as a process step requiring cleaning and may be a key contributor to improved core quality. SUMMARY Eliminating bad cores from the casting defect scenario is not difficult. It does take close monitoring and requires a well thought out and thorough action plan that includes checklists for recordkeeping for each job. Initiating simple process changes, maintenance procedures, and understanding new core machine and its supporting systems can help deliver consistent core quality. Making good quality cores is a combination of many factors. Simple changes can dramatically improve the foundry’s profitability, employee safety, and workplace environment. DEFECT PREVENTION