Committed to sharing best practices for the metalcasting & die casting industry THIS ISSUE'S FOCUS HIGHLY TECHNICAL TOOLBOX ISSUE 20 • SPRING 2024 WELCOME TO OUR 20TH EDITION
The articles in this edition detail important toolbox reference materials for the latest metalcasting technologies including digital integration, real-time data collection, and the transformative impact of artificial intelligence on the foundry floor—and everything in between—such as compacting, conveying, testing, and important equipment calibrations. Simple Solutions That Work! isn't just a magazine; it's a comprehensive collaborative resource designed to empower you with the knowledge needed to excel. All of the reference material and insights presented are sourced from innovative suppliers currently implementing these cutting-edge technologies on foundry floors, globally. While there are a number of excellent organizations that support the foundry industry, we believe there is high value in sharing experiences and discussing day-to-day problems—and solutions. As technology evolves, so too do the fundamental principles of "How to properly do that." The future of metalcasting is unfolding before us, and we appreciate our contributors through the years for their invaluable insights and solutions. As always, thank you for reading our 20th issue of Simple Solutions That Work! Yours in Metalcasting, Jack Palmer President Palmer Manufacturing & Supply, Inc. [email protected] PS. All past issues of Simple Solutions That Work! are produced in PDF format for easy download from our web: palmermfg.com/simple-solutions.php WELCOME TO OUR 20TH EDITION A REFERENCE GUIDE FOR TODAY'S METALCASTING SOLUTIONS WANT TO SEE MORE? VISIT OUR WEBSITE TO GET PAST ISSUES! palmermfg.com/simple-solutions.php PALMER MANUFACTURING & SUPPLY INC. PUBLICATIONS © 2024 Palmer Manufacturing & Supply, Inc. All Rights Reserved
Act Now to be considered for the Simple Solutions That Work! Fall 2024 publication and reach over 40,000 metalcasting/die casting industry contacts in North and South America. CALL 937.654.4614 or email [email protected] SIMPLE SOLUTIONS THAT WORK! ENGLISH Welcome to our 20th Edition A Reference Guide for Today's Metalcasting Solutions. ......... 02 Jack Palmer - Palmer Manufacturing & Supply, Inc. Women in the Foundry.................................................. 04 Barb Castilano, Editor Mold Coatings for Release & Protection............................ 09 John Hall - CMH Manufacturing Company Hands-off Blasting: The Next Frontier in Digital Shot Blasting. ......................... 11 Joe Everett - Wheelabrator, Norican Group Using the Compactibility Test to Optimize Green Sand Quality....................................... 15 Michelle Ring - SIMPSON, Norican Group Artificial Intelligence is impacting the Foundry Floor — Are You Ready?...................................................... 19 Nina Dybdal Rasmussen - Monitizer, Norican Group New Demands Require New Tools in the Toolbox................. 23 Jeff Keller - Molten Metal Equipment Innovations, Inc. Using Sand Data to Communicate Performance Metrics......... 27 Jeff Zurface - The Schaefer Group, Inc. Improve Production by Upgrading Existing Equipment........... 31 Jack Palmer - Palmer Manufacturing & Supply, Inc. Design TIps for Pneumatic Sand Transporter Systems. .......... 33 Jim Gauldin - Klein Palmer, Inc. Riser Design Basics for Cast Irons. .................................. 37 Dave C. Schmidt - Finite Solutions, Inc. Ladle Preheaters & Refractory Linings—An Integral Unit....... 41 Steven Harker - Acetarc Engineering Co. Ltd Digital Servo Reciprocating Spray Systems for Die Casting Machine................................................ 45 Troy Turnbull - Industrial Innovations, Inc. Foundation Loading Guidelines....................................... 49 Jerry Senk - Equipment Manufacturers International, Inc. Tools & Tips: Additive Manufacturing Update...................... 51 Will Shambley - New England Foundry Technologies A Comparison of Traditional Steel vs. Additive Manufacturing for Molds & Dies........................... 54 Russ Bowen - Molder's World, Inc. New Generation of Phenolic Urethane Resin Systems Reduces VOCs............................................................ 56 Rick Yrigoyen - United Erie, Inc. Electric Melting: The New "Green Technology" Furnace.......... 59 David White - D and S Consulting LLC TABLE OF CONTENTS ESPAÑOL Bienvenidos a la vigésima edición su guía de referencia de las soluciones actuales en fundición y metalurgia.................... 64 Jack Palmer - Palmer Manufacturing & Supply, Inc. Mujeres en la Fundición................................................................................................ 66 Barb Castilano, Editora Pinturas Desmoldantes & Protectoras para Molde Permanente...................................... 71 John Hall - CMH Manufacturing Company Granallado “sin manos”: el siguiente Hito en el Granallado Digital....................................................................... 73 Joe Everett - Wheelabrator, Norican Group Ensayo de Compactibilidad para Optimizar la Calidad de la Arena de Moldeo en Verde.................................................................................... 77 Michelle Ring - SIMPSON, Norican Group La Inteligencia Artificial está impactando las Plantas de Fundición ¿Está usted preparado?................................................................................................. 81 Nina Dybdal Rasmussen - Monitizer, Norican Group Las nuevas necesidades exigen nuevas herramientas.................................................... 85 Jeff Keller - Molten Metal Equipment Innovations, Inc. Integración de Datos del Horno...................................................................................... 89 Jeff Zurface - The Schaefer Group, Inc. Mejore su Producción al Modernizar sus Equipos........................................................... 93 Jack Palmer - Palmer Manufacturing & Supply, Inc. Consejos de Diseño de Sistemas de Transporte Neumático de Arena.............................. 95 Jim Gauldin - Klein Palmer, Inc. Diseño Básico de Montantes al Fundir........................................................................... 99 Dave C. Schmidt - Finite Solutions, Inc. Revestimientos Refractarios & Precalentadores de Cuchara: una unidad...................... 103 Steven Harker - Acetarc Engineering Co. Ltd Sistemas Digitales de Rociadores Servo-Reciprocantes Para Colado en Molde Permanente................................................................................................. 107 Troy Turnbull - Industrial Innovations, Inc. Lineamientos Para Cálculos de Fundaciones................................................................ 111 Jerry Senk - Equipment Manufacturers International, Inc. Herramientas & Consejos: Actualización en Manufactura Aditiva.................................. 113 Will Shambley - New England Foundry Technologies Una Comparación Entre Aceros Tradicionales vs Manufactura Aditiva Para Moldes................................................................................ 116 Russ Bowen - Molder's World, Inc. Nueva Generación de Resinas Fenólico Uretánica Reduce VOCs............................................................................................................... 118 Rick Yrigoyen - United Erie, Inc. Fusión Eléctrica: El Nuevo Horno de “Tecnología Verde”............................................. 121 David White - D and S Consulting LLC
4 Despite advancements, manufacturing remains a male-dominated industry, with women, particularly in the metalcasting sector, continue to be significantly underrepresented. It underscores the ongoing need to promote the many opportunities and foster diversity within this field. Today, we are putting the spotlight on accomplished women in upper management positions within the metal casting industry. This feature showcases leaders from both foundries and foundry suppliers, sharing their successful journeys in positions traditionally dominated by men. WOMEN in the FOUNDRY Gwen Krenecki President, Lodi Iron Works Andrea Hefty Lindquist General Manager, Sure Cast Foundry Nina Dybdal Rasmussen Senior Vice President & Head of Monitizer, Norican Group
TECHNICAL TOOLBOX ISSUE 5 Continued on next page How did you fall into the metalcasting industry? GK: I am a 3rd generation of my family’s business, Lodi Iron Works. I also received my undergraduate degree at Cal State-Chico where I received an FEF scholarship. AHL: I have been in manufacturing for my whole career, starting in the automotive industry as a manufacturing engineer for Toyota. My career progressed through several industries and increasing job responsibilities cumulating in executive leadership. Five years ago, I was approached by a recruiter looking for an experienced manufacturing operations professional to take a Vice President of Operations position at an iron foundry and that is where I fell into this industry. NDR: When I applied for a job at DISA 18 years ago, I had little knowledge of the metalcasting industry. My background was in B2B marketing, and I held a Master’s in International Management. But I really wanted to work for an international company and had always enjoyed collaborating with engineers. My introduction to the metalcasting industry began as soon as I stepped into the DISA production facility. Witnessing a DISAMATIC molding machine in action, producing real aluminum castings in their trial facility left an indelible impression on me. I particularly recall the moment I touched the compacted sand mold and began to understand the remarkable technology behind this process. The concept of repeatedly recycling almost all of the sand fascinated me, as well as the diverse range of castings that could be made. What is your opinion on gender roles in the metalcasting industry? GK: I believe both genders are very capable in several roles. I do however believe that women tend to be better at multitasking. AHL:The automatic assumption is a woman cannot mold and pour metal. Every factory I have ever worked in has had a large population of female production team members. But you rarely see a woman in production in a foundry. Why not? Of course, it is dirty and heavy work, but women can do that work just as well as men. Just as a woman can be an engineer, a pilot, a doctor. Nothing should preclude women from this industry. I do not feel that this industry has been inclusive to women or in search of women. We need to get out there and make it known there are opportunities here. NDR: Nearly two decades ago, when I first entered the industry, it was predominantly a male environment, especially in technical and managerial roles, with very few women around. However, I have started to see a positive shift since we've been openly addressing gender inequality in the industry. It's important to note that this change is very slow, and we are still in the early stages of companies actively embracing and advocating for diversity and the numerous benefits it brings. This progress will only endure if we continue to proactively drive and show diversity - through interviews like this one, for example. What has been your biggest accomplishment in your career? GK: Watching our employees grow in their foundry knowledge has personally been a source of enormous pride. AHL: When I started out of college, my dream was to work in the automotive industry. I made it happen and succeeded. But, over the years, my career has taken turns and curves that I often did not expect or plan for. If you had told me 25 years ago that I would not still be in the automotive industry today, I would not have believed you. I had a poster in my dorm room that showed a girl coming to a fork in the road with a sign pointing out two different paths and you see her proceeding down one of the paths. The sign pointing down one fork of the road said “no longer an option” and the other side of the sign pointing down the other fork said “your life now.” The girl was proceeding down that path. My biggest accomplishment has been my ability to pivot with what my career and life throws at me. Taking on challenges I never thought I would. Diving into new industries head first with no previous experience. Pressing on through setbacks and curveballs that were unexpected. That is the greatest accomplishment for me. NDR: I am particularly proud of how far I’ve progressed in my career, considering my background as a young female without an engineering background. I've been fortunate to have had managers who consistently entrusted me with substantial responsibilities and provided remarkable job opportunities, where others might have hesitated to do so. This trust allowed me to demonstrate my capabilities and ultimately led me to my most substantial accomplishment to date: being entrusted with the opportunity of leading Norican's Industrial Internet of Things brand, Monitizer®, and spearheading Norican’s digital strategy.
6 Do you feel there is enough information and opportunities for the next generation to be encouraged to have a career in the metal casting industry? GK: This is a tough question. We are located in California where we do not have many foundries left. Additionally, schools nationwide have consolidated metallurgy into material science. All of this has resulted in an overall loss of knowledge—at the same time the industry is embracing newer technologies into our processes with can improve how things are done. AHL: I do not. In engineering school, I took one required class on material science and metallurgy. At the time, it was not for me. My focus was on production, quality and efficiency. And until I was recruited into the industry as management and a leader, I did not know much about it. It was a crash course in foundry and every day I learn more. As I stated in the question above, I do not feel metal casting is something that is shown to women as a choice whether that is in educational settings or in marketing of the industry. It is also not an industry you often see recruiting at universities, colleges, trade schools, and technical schools. I think there are greater opportunities to market to both men and women. NDR: There are definitely plenty of opportunities. The industry is getting more and more interesting and increasingly requires big picture thinking and the ability to connect different fields and disciplines. I started out marketing molding machines, today I’m running an AI and IIoT start-up and am laying the foundations for the future of foundries, together with talented colleagues around the world. Is there enough information about those opportunities? Probably not – but we’re working on it. Advice you give to women entering a male dominated environment? GK: You got this! AHL: Be yourself and do your best work. You are no different from your male colleague and what you have to contribute is comparable or better! Persistence is key. Do not give up. I am not going to lie and say that, at times, you need a thick skin. But, do your best to let things that rattle you, roll off of you and stand up for yourself. Being a woman in a male dominated industry or field does not mean you need to be more aggressive or mean to be seen. Put your head down and work hard and accept who you are as woman and do not change just to conform to the environment. NDR: I believe it's crucial for women entering a predominantly male environment to be confident about what they bring to the table. Diversity – of people, ideas, lived experiences - is a good thing and drives organizations forward. I strongly encourage women to define their career ambitions clearly and express them with confidence. If possible, seeking out a mentor or role model who can offer guidance and support is immensely valuable. This doesn’t have to be a woman, someone at the same company, or even someone you meet face to face. Choosing a company that places a high value on diversity can also be a strategic step in navigating industries that are still considered “male industries”. How important do you feel female role models are to the younger generation, and do you have one? GK: Role models are a game changer. I had my grandmother before me, that showed me women could do anything they wanted. My grandmother bought Lodi Iron Works in 1963 and ran the business successfully until she passed away in 1999. NDR: I find role models to be incredibly motivating as they can serve as a source of inspiration to pursue one's ambitions or help guide the way. I've been fortunate to have had a female role model throughout my entire career at Norican, someone who has paved the path all the way to the position of president. Not everyone is so fortunate to have a trailblazer in their business, but there are many inspiring female voices out there. You can find them writing about their experiences on LinkedIn or talk at industry events. They are a great source of inspiration and worth connecting with. Anything else you would like to add about working in such a male dominated field? NDR: I have always relished the experience of working in a predominately male and engineeringcentric industry because I find it inspiring to be surrounded by individuals whose perspectives differ from my own. However, I am aware that I have been very lucky throughout my career, and I consider it my responsibility to pay this forward. It’s what I’m aiming to do in my own teams, by championing diversity and by offering a window into our exciting industry as much and as often as I can.
TECHNICAL TOOLBOX ISSUE 7 All these leaders discovered significant opportunities upon fully immersing themselves in the metal casting industry. Their experiences strongly reinforce the belief that when this industry highlights its opportunities, it paves the way for the next generation to pursue rewarding careers in the challenging field of metalcasting. Going forward, all manufacturing will depend on a diverse workforce which will present more growth and leadership opportunities for women. We intend to keep this series going with the objective of inspiring more women to learn from others about the pathways to success in metal casting. Contact: BARB CASTILANO, editor [email protected]
April 23-25, 2024 I Milwaukee, WI VISIT US IN BOOTH #754
TECHNICAL TOOLBOX ISSUE 9 Continued on next page MOLD COATINGS FOR RELEASE & PROTECTION Permanent mold coating is one of the operational parameters of the casting process that is often overlooked or misunderstood. Permanent mold coatings are necessary for three basic reasons: 1. Coatings provide a protective barrier between the mold and the casting to prevent mold erosion and wear. 2. Coatings provide some degree of control over the solidification rate and direction. 3. Coatings provide a barrier between the mold and the casting so that the casting will release from the mold. JOHN HALL President CMH Manufacturing Company With proper use, a permanent mold coating can be used to control the thermal gradients such that directional solidification can be achieved. This allows a pathway for feed metal to flow into the solidifying structure and compensate for normal metal shrinkage during solidification. This is particularly important in castings with thin sections changing to think sections. The thin areas must remain open to ensure that shrinkage will not occur in the adjacent thick section. In some casting designs there might be two or more characteristics working against one another. For example, a design might have a thinwalled section in need of additional insulation to prolong solidification yet is also in an area that is difficult to release from the mold. In this case a compromise must be reached. By their very nature release coatings are not insulative and insulative coatings will not aid in the release of tight or difficult geometries. In such cases a choice must be made as to which of the two operational characteristics is most important. One choice may be to use a combination coating that will allow for some insulation and some release. Another option is to use an insulating coating as a base coat and a release top coat. Insulation coatings can vary greatly in insulating qualities as well as the surface finish the coating will impart to the casing. The insulating qualities of a coating are a function of the type of refractory filler that is used and their thermal conductivity and heat capacity. Also contributing to a coating’s insulative capabilities, as well as surface finish, is the amount of binder and the dilution rate. Typically, binders are a sodium silicate. Typical refractory materials found in mold coatings include: vermiculite, bentonite, talc, titanium dioxide, alumina, olivine, and graphite. Release and chill coatings both contain materials that act as heat conductors to allow for more rapid solidification while protecting the mold against wear. Release coatings typically contain graphite as the lubricant, which is non-wetting by aluminum. MOLD COATING APPLICATION As in any coating application, surface preparation is critical. New molds should be thoroughly cleaned. Molds that have been in service must have all the old coatings completely removed. The type of cleaning media used varies and includes sand, metal shot, grit, glass beads and dry ice (CO2). The choice depends on availability as well as how difficult the coating is to remove. In most cases it is recommended the dry ice blasting be used for routine cleaning with periodic sand blasting to restore the mold surface finish for mold coating. Over blasting, especially with sand, shot, or grit, can erode mold detail and shorten mold life. ARTICLE TAKEAWAYS: • Increase permanent mold life with coatings • Coating preparation, application and storage
Mold coatings should be sprayed onto the mold surface with an airless spray gun or an aspiration type spray gun. Spraying equipment may be one of many different styles and types of spray guns. Use of a paint gun is not recommended as the heavy materials in the mold coating easily clog the small ports. A siphon type gun that has one straight fluid tube with replaceable fluid tips works well. Some siphon guns are available with interchangeable pots. With extra pots, two or three different types of coating may be kept on hand, mixed and ready. As the need arises for a particular coating, it may be snapped on the spray head and used immediately. In areas where a high degree of insulation is required, such as gates, runners, risers and pouring cups, brushing the coating on will provide more insulating capability. In addition to the insulating properties of the coating itself, brushing will trap air bubbles, which enhance insulation. Additionally, the rough surface caused by brushing can aid in molten metal flow through the gating system by continuously disrupting the oxide skin as the metal flows. Thoroughly mix the coating in its original container before diluting or using only a portion of the can weight. This will alleviate any settling problems that can occur during transit and storage. When diluting, soft warm water works best, but cold water is acceptable. In either case, adequate mixing with any equipment such as a Lighting mixer or a bent rod in a hand drill is required. Excessive shear should be avoided. The mold should be heated to 600°F (315°C). Care must be taken to heat the mold uniformly. Optical pyrometers should be used to determine if the mold is heating evenly. While the mold is hot it should be sprayed lightly with water. This will increase a porous oxide film on the mold, which will provide a good surface for the mold coating to bond to. The water spray also cools the mold to the desired coating application temperature, 350° - 400°F (75° - 200°C). If the molds are too hot, the rapid expanding water vapor front moving away from the mold will cause a phenomenon known as “kick back,” and very little coating will adhere to the mold. Even the coating that does adhere will not be properly bonded. If the mold is too cold the coating might run resulting in an uneven surface. Depending on the brand of coating, a primer coat may be required. This could be a specifically designed primer or a diluted version of the main coating. The purpose of the primer coat is to create the best possible adherence of the coating to the mold. This occurs because very diluted sodium silicate solutions allow for bonds that are more parallel to the mold face. This structure forms a stronger bond, which is more resistant to wear. In contrast, high sodium silicate solutions create bonds that are perpendicular to the mold face and can be sheared off. Care must be taken not to over dilute the primer coating, as sufficient sodium silicate must be present to generate the bond. Once the primer is applied, the main coating can be applied at higher concentrations. Do not try to cover the mold face with one heavy coating. A gradual buildup of the coating is preferred over one heavy coat. The number of coats and the exact coating thickness will vary with the casting design and may vary within the mold itself. A working profile should be developed for where a heavier or thinner application of coating should be applied to aid solidification. After the coating has cured, excess coating should be removed from the parting line and core prints with a wire brush or soft brass scraper. As noted, most all commercial mold coating materials are bonded by sodium silicate with various filler materials for their insulative, lubricative or cosmetic qualities. STORAGE Mold coating is supplied in fivegallon cans or fifty-five-gallon drums. The coatings should be stored in their original covered containers with the lids firmly in place when not in use. Mold coating should be stored in a dry place away from excessive heat or cold or drastic temperature change. Ideal storage temperatures range from 50°- 75°F (10°- 25°C). Under no circumstances should the coating material be allowed to freeze, as subsequent thawing may not restore the coating to its original condition. Refer to the coating manufacturer’s instructions for additional storage information. Contact: JOHN HALL [email protected] 10
TECHNICAL TOOLBOX ISSUE 11 Traditionally, it took experienced and skilled employees to keep a shot-blast process on track and machines in peak operating condition. At an alarming rate, this experience and skill is retiring and is increasingly hard to replace. As equipment gets more and more automated, the risk of small issues becoming unscheduled outages is real. When things go wrong with shot blast equipment, operating costs can ramp up rapidly, especially when excess abrasive consumption, energy use or downtime are not fully understood or go unnoticed by operators and management. Even at the best companies, advances in shot blast technology over the last two decades have nearly exhausted the potential for process optimization and automation. Today, significant gains and reliable, handsoff process control, can only be unlocked with digital integration. Digital integration and real-time data collection in shot blast machines offer companies the ability to closely monitor operations, promptly identify anomalies, receive alerts for potential issues, and intervene proactively. This approach significantly reduces the risk of minor operational hiccups escalating into major problems, ultimately enhancing operation efficiency, and minimizing downtime. (see customer example below). Most importantly, you build a history of data on your own process to analyze and learn from. This additional know-how can be built into dashboards and alerts, to ensure fewer and less experienced operators can monitor the process and look after the machine. The results? A more stable process, higher quality output, and more efficient resource and energy use. A FAST START TO DIGITALLY ASSISTED BLASTING A network gateway is all it usually takes to digitally-enable even older shot-blast machines. These edge devices collect data from PLCs, sensors and other sources and send them to a central platform. We use the Monitizer® NoriGate solution to digitally enable Wheelabrator equipment. This solution can also be installed on many types of equipment from almost any vendor. Available in real time for monitoring, the data can also be stored in an existing Industry 4.0 system or a cloud application. Through it, data can be accessed, viewed, and analyzed on easily configurable dashboards or using pre-set tools. If data is being collected across an entire process, shot-blast data not only helps improve blast operations but can generate insights into how other parts of the process can be improved too. For example, data on reasons for machine idling can point to issues with production flow, while feedback from the abrasive recycling system could indicate a problem during shake-out on a molding line. CUT BLASTING COSTS Using digital integration to reduce blasting costs delivers the biggest gains early on and rapidly covers the cost of the initial digital installation. A set of ready-made, proven digital tools is available to tackle the top three shot-blast cost drivers: energy use, abrasive consumption, and maintenance. To give an example of the potential payback, a digital tool that reduces idle time by one hour per day could save over $10,000 annually in energy cost alone (on a machine with eight 50HP blast wheels, running in three-shift operation, 240 days a year). But the benefits extend well beyond those three metrics. Optimizing abrasive consumption can shorten cycle times, save energy, and reduce wear, while cutting energy use (through the clever management and minimization of idle time) and minimizing maintenance can free up capacity and maximize productivity. HANDS-OFF BLASTING: THE NEXT FRONTIER IN DIGITAL SHOT BLASTING JOE EVERETT VP Business Development North American Market, Wheelabrator ARTICLE TAKEAWAYS: • Real-time data collection to monitor operations • AI puts “self-correcting blast process” within reach Continued on next page
Contact: JOE EVERETT [email protected] Beginning in this simple way helps operators, production managers and engineers learn more about their process and how to extract knowledge from the data — expertise they can apply and extend in future. CASE STUDY — REDUCING WASTE WITH DIGITAL MONITORING At one premium tool manufacturer who piloted our solution early on, forged parts were blast-cleaned and then coated, so blasting had a major influence on product quality. The business had reduced rework rates substantially using conventional techniques but realized that it needed data-driven insight to identify further improvements. For the pilot project, it digitized a Wheelabrator Tumblast machine to make real-time process data available. With its process now dashboards were created to generate and track relevant metrics and KPIs. One of the most important goals was to constantly optimize the abrasive mix which would have a major influence on blast quality, intensity, and stability. Digital data revealed regular unexplained spikes in abrasive consumption which turned out to be the rotary screen clogging due to insufficient cleaning — a simple maintenance error. Clogged screens meant the abrasive overflowed, straight into the waste. Discovering and correcting this error significantly improved process stability, cut abrasive consumption and reduced the rework rate. With real-time digital monitoring, a traffic light system alerts operators and managers if target values are exceeded. The company can now better control and stabilize its blast process — and so improve quality. The project lead at the customer said: “The operating mix has been easy to neglect because you have to go up the ladder on the machine and look inside to check the screens. When something goes wrong, you often only see it at the end; and that means rework. With one glance at the dashboard, we can see when maintenance is needed and can intervene before the blast process runs off course. We are finally driving with a clear view of the road ahead.” ARTIFICIAL INTELLIGENCE FOR BETTER BLAST MACHINE MAINTENANCE The digital tools described above are effective, but only a starting point. Their delivery platform is capable of running even more advanced digital technologies such as artificial intelligence (AI). These tools can cut shot-blast maintenance (through AI-driven early warning systems, for example) and cost. They could even eliminate unscheduled downtime entirely, making better use of scarce maintenance personnel. For maintenance-intensive equipment like shot-blast machines, this could be a game changer. Another development currently underway employs digital image analysis to monitor abrasive condition in real time. The idea: automatically recognize substandard abrasive particles to keep the operating mix at the precise optimum. This opens the door to completely automatic, digital process control. Advanced process control tools for high-spec blast processes have enormous potential, with almost no limit to the number and type of data feed they can process. From built-in AI capabilities to automatic 12 corrective measures that kick in when set values are exceeded — we are not that far away from a selfcorrecting blast process. TRANSFORM BLAST PERFORMANCE Current digital applications monitor process parameters and tackle the main shot-blast cost drivers, but there is immense additional potential for improved process control and traceability. Once you’ve digitally enabled a machine and start collecting, storing and analyzing process data, it’s easy to take the next step: add further sensors, run extra analyses or add enhanced digital applications. By finally overcoming some of blast equipment’s historic challenges, digital technology will put operators in the driving seat, give them greater control, a more modern, safer working environment and greater scope for collaboration and learning. This is vital when skilled labor is scarce: the digital system supports experienced operators, enabling them to do more, while helping to train the less experienced staff. Digital tools make it straightforward to enhance your shot blasting process. They are user-friendly and offer a quick return on investment. They don’t necessitate specialized skills; rather, they bring valuable insights and expertise to your operations. These insights have the potential to bring about a transformative and positive change in your blast operations, ultimately leading to long-term improvements in performance and efficiency.
CT Continuous Through-Feed Tumblast Machine Unlock the power of automatic, continuous & dust-free blast cleaning • High capacity | Fast cleaning | Less contamination | Better safety • More efficient because it adapts automatically to load • Full exposure of all workpiece surfaces to the blast stream • Fully digitally enabled wheelabratorgroup.com Norican Technologies Continuously Increases Your Profits Less downtime means greater volume of products produced in less time CT Continuous Through-Feed Tumblast Machine Unlock the power of automatic, continuous & dust-free blast cleaning • High capacity | Fast cleaning | Less contamination | Better safety • More efficient because it adapts automatically to load • Full exposure of all workpiece surfaces to the blast stream • Fully digitally enabled wheelabratorgroup.com Norican Technologies Continuously Increases Your Profits Less downtime means greater volume of products produced in less time CT Continuous Through-Feed Tumblast Machine Unlock the power of automatic, continuous & dust-free blast cleaning • High capacity | Fast cleaning | Less contamination | Better safety • More efficient because it adapts automatically to load • Full exposure of all workpiece surfaces to the blast stream Fully digitally enabled wheelabratorgroup.com Norican Technologies Continuously Increases Your Profits Less downtime means greater volume of products produced in less time
Have confidence in your sand Casting defects not only affect quality, they impact your profit margin and competitiveness. The good news – there is a standard test for every defect and Simpson offers the solution! Want to know more? Contact us today: 630-978-0044 or [email protected] simpsongroup.com
Figure 1: Sketch of a compactability sample before and after a force is applied. BUT WHAT EXACTLY IS COMPACTABILITY? Compactability measures the percentage by which a loosely packed sample compresses under applied force, representing the decrease in height of a specific sand volume, as shown in figure 1. Typically, green sand compactibilities range from 35-50%. The test is highly responsive to changes in moisture. The results aid in monitoring moisture levels and guides water additions during the mulling process. As the force is applied to the top of the sample, the sample compacts; the higher the compactability, the more the sample was able to compact in height. The compactability is critical; if it is too low, a result could be friable edges, difficulty drawing pockets, penetration, and crush defects. If the compactability is too high, it can cause poor surface finish, expansion, gas, shrink, pinholes, and blow defects as well as mold-wallmovement which can lead to swell and oversized castings. For many years the 3-ram compactability test was used throughout the foundry. A 3-ram unit could be found at the muller deck and in the sand lab. The test was used to help determine the water addition to the muller. The development of the automatic compactability controller (molding unit) and digital pneumatic sand squeezer (laboratory) has replaced many traditional 3-ram units. The units are shown in figure 2. TRADITIONAL 3-RAM TEST The 3-ram test, dating back to the 1920s, was a significant improvement over the hand-feel method. A sample of green sand is riddled through an AFS standard ¼” screen and funnel assemble into the specimen tube and struck off evenly at the top of the cylinder. The plunger head is raised, and the specimen tube with base is placed underneath the head. It is important to carefully place the specimen tube into the machine, to prevent any pre-compaction. The head is lowered slowly, ensuring additional weight/force is not added to the sample. Next, the cam is slowly turned to raise the weight above the sample and the weight free falls onto the sample, compacting the sand. The dropping of the weight is repeated 2 more times. The operator then reads the value on the vernier scale. History Lesson: Why 3-rams; Why Not 4? Ries and Nevin determined the 3 drops was the ideal amount by dropping a ball bearing on a mold at a steel foundry. The impression was measured. Then back in the lab, it was determined that it took 3 drops of the sand rammer weight to reproduce the same diameter impression on the test specimen. Thus 3 rams of a 14-pound weight falling 2” was developed. More recent studies have proven it is an acceptable procedure. MICHELLE RING Technical Services Manager SIMPSON ARTICLE TAKEAWAYS: • Understanding green sand compactability • Compactibility testing: Best practices Continued on next page Compactability is one of the most essential and common tests in foundry green sand. The ability to properly measure and control compactability, allows the foundry to reduce variation in other parameters, including green strength, moisture, friability, flowability, cone jolt, density, permeability, and wet tensile. Basically, every green sand test except GFN and sand distribution. 15 USING THE COMPACTABILITY TEST TO OPTIMIZE GREEN SAND QUALITY TECHNICAL TOOLBOX ISSUE
DIGITAL PNEUMATIC SAND SQUEEZER TEST The digital pneumatic sand squeezer has been widely accepted as a better representation of the compressing action similar to an automatic molding machine than the rammer. The digital readout also eliminates potential operator reading error, as it is much simpler to read a number than lining up a ruler scale. The pneumatic tester consists of a pneumatic regulator and a valve that controls the feed pressure into a cylinder. The compactability, displacement and squeeze pressure are automatically calculated and digitally displayed after the cylinder compresses the sand sample. SPECIMEN WEIGHT WITH THE DIGITAL TEST Bulk density is inversely proportional to compactability. Since different sands have different densities, moisture contents, and other compositional differences, the amount of sand required to make a standard sand specimen can vary from foundry to foundry and from day to day. If you do not know the sand weight required to make a standard sand specimen, then start with approximately 165 grams and you can enter this starting sand sample weight into the digital pneumatic squeezer. With the starting sand weight programmed into the squeezer, the exact weight can be determined automatically by the squeezer after the first test is completed. Figure 2: (a) Sand Rammer (b) Digital Pneumatic Sand Squeezer and (c) The Automatic Compactability Controller Figure 3: A Summary of results of the Pneumatic Digital Squeezer and the traditional 3-ram on the same sand sample for 6 green sand systems from 2022 AFS Sand Casting Conference 16
COMPARISON DATA BETWEEN TEST METHODS A group of foundries, as part of the AFS 4M Green Sand Committee, ran the pneumatic compactability tester alongside the 3-ram test. The results of the study were presented at the 2022 AFS Sand Casting Conference. The summary in figure 3 shows that the tests results consistently trended together and demonstrated a strong correlation. The pneumatic showed slightly higher values than the 3-ram on the same samples. It was generally agreed that the foundries could adjust their lab specifications accordingly and replace the 3-ram test with the pneumatic squeezer. BASIC TESTING BEST PRACTICES: For foundries that run a 3-ram test: - Gently rotate the cam arm to lift the weight, allow the weight to “drop” three times. Be sure not to ram the sample too quickly. Allow the weight to rise above the cam and fall from a higher than designed position as it prevents an additional force being applied to the sample. A recommendation is to pause at the “4:00” position in between rams. - Proving or Impact rings are suggested to confirm rammer energy. For the pneumatic test: - It is important to periodically check the oil/lubricant setting and addition rate as well as the pressure setting at the pressure regulator. If this is not properly maintained, the results may be incorrect, and could damage the cylinder in the machine. The oil addition rate is one drop of oil for every 3-4 cycles. - A voltage stabilizer/filter (line conditioner) is recommended to stabilize the performance of the testing equipment. For both laboratory compactability testing methods: - Sand should be struck off from the center of the tube to the right and then to the left. A specimen tube should be clean and lightly lubricated every time a sample is made. - It is recommended that a small amount of parting liquid be periodically applied to the tube swab. If not, the result will be a higher compactability reading, lower Green Compression Strength, and higher permeability than if the test was properly performed. - Specimen tubes should be checked regularly for rust, pits, or excessive wear. Accurate measurement of compactability empowers foundries to make informed adjustments, enhancing green sand quality and ultimately producing superior castings. Adhering to best practices ensures the reliability of test results and contributes to the continuous improvement of foundry processes. FOR MORE INFORMATION: Krysiak, M. B., Keener, T., & Schlotta, B. (2002, February). Optimum sand testing requires reliable rammers. Modern Casting, 30–32 Dietert, H. W. (1967). The Era of Sand Testing. AFS Granlund, M. J. (1999). Understanding the Basics of Green Sand Testing Volkmar, A. P. (1970). System Sand Control by Compression vs Compactability Testing. AFS Modern Casting Staff. (1976). Determining the Compactability of Molding Sand Mixtures Rammer Method — Tentative Standard; Determining the Compactability of Molding Sand Mixtures Laboratory Squeezer Method — Tentative Standard Alagarsamy, A., & AFS Molding Methods & Materials Div. Basic Concepts Committee (4-E). (2002). Controlling Green Sand Compactability Gerth, C; Nelson, A; Snow, B; Bryant, N. “Pneumatic vs 3-Ram Compactability Testing.” AFS 2022 Sand Casting Conference, Sept 2022 Contact: MICHELLE RING [email protected] TECHNICAL TOOLBOX ISSUE 17
Turn your data into value with Monitizer® Norican Technologies Proven Industry 4.0 Platform for Every Foundry Collect Visualize Analyze First test results from four different patterns showed an average scrap rate reduction of 57.2%. We are amazed by these results. “ ” • All you need to collect, visualize and analyze your data • Connect to ANY data source on ANY machine • Unlock insights that cut costs, defects and downtime • Proven powerful AI to cut scrap in green sand foundries by 40% Scan here for more information —Mr. Shaung, Huaxiang Foundry on Monitizer | PRESCRIBE Turn your data into value with Monitizer® Norican Technologies Proven Industry 4.0 Platform for Every Foundry Collect Visualize Analyze First test results from four different patterns showed an average scrap rate reduction of 57.2%. We are amazed by these results. “ ” • All you need to collect, visualize and analyze your data • Connect to ANY data source on ANY machine • Unlock insights that cut costs, defects and downtime • Proven powerful AI to cut scrap in green sand foundries by 40% Scan here for more information —Mr. Shaung, Huaxiang Foundry on Monitizer | PRESCRIBE
Just as some were skeptical about the influence that robotic automation would have (remember robots painting robots?), some today are skeptical regarding Artificial Intelligence’s ability to resolve bottlenecks, adjust energy consumption, and send alerts before equipment begins to fail, preventing expensive downtime. Others too, are concerned about their place in all of this. In this Q&A we will explain how AI is deployed in the foundry floor for the highest level of automation optimization, and the key role that operators will have in setting targets and making important judgement calls to respond to real-time data telling them that attention is required. Multiple global foundries have now harnessed AI to cut scrap by a staggering 86% per pattern, shrink their costs and reduce emissions. But simply buying an AI solution and expecting that alone to make a difference is naïve. Technology, data, people, and internal systems must all come together and work in harmony to derive real and lasting value from an AI investment. Proven change management techniques — such as those in the classic 8-step Kotter model — are central to realizing AI’s potential for foundries. Whether it’s vertical and horizontal green sand molding, or high pressure and low pressure die casting, a commitment to change management is the common factor amongst the leading foundries that have successfully implemented, or are implementing AI-driven optimization. NINA DYBDAL RASMUSSEN Senior Vice President & Head of Monitizer Norican Group ARTICLE TAKEAWAYS: • Understanding AI and its foundry floor applications • Technology, data, people, and internal systems must work in harmony • Success requires a commitment to change management Continued on next page “Hands off and lights out” AI-controlled process automation for foundries might sound revolutionary but it’s already starting to happen. With the right infrastructure and processes in place — and a successful change management program — it could be part of your future too. 19 ARTIFICIAL INTELLIGENCE IS IMPACTING THE FOUNDRY FLOOR — ARE YOU READY? TECHNICAL TOOLBOX ISSUE New technologies have been at the forefront of Industry 4.0 for obvious reasons. Most can understand the economic benefit of reducing downtime, energy, and scrap — that’s the easy part. The hard part is wrapping your head around ever-increasing computing power, machine learning and using data analytics to make it all happen.
20 If your company is ready to drive forth, here are some foundation questions and answers to set your course: Q&A FOR UNDERSTANDING AI AND HOW TO GET STARTED Q: In addition to the obvious machine wear/tear alerts, what other value can AI add? A: Eliminate day-to-day operational setbacks and be able to highlight actionable insights for C-levels using engaging charts and graphs. As an AI deployment creates a holistic data-based view of the entire foundry process, it often reveals — and helps remedy — problems with current methods. One example is a customer’s quality system that reports completely different batch volumes compared to the rest of the line. That makes it impossible to build a working process model but is usually easily resolved. AI presents data in real-time with KPI dashboards to visually show and alert the operator to important indications that can prevent breakdowns, reduce energy consumption or other targets that are set by the operator. Understanding fully how to implement AI-suggested parameters is another vital enabler. Which machine settings do operators change and by how much to reach the ‘AI control zone’? Make sure the operators know how to achieve this. To make it happen, an AI vendor who completely understands foundry machinery and processes is essential. To understand exactly what is happening with its process and sensecheck what the AI is recommending, the foundry must give its expert users full access to process data — and the tools to report on and analyze it. But an IIoT cloud database can make process and all other data linked to it visible (ERP, quality, maintenance) to any permitted user, so think about where else that data could deliver added value. Monitoring and alerting on the line are obvious applications but you could also think about business intelligence reporting for your CFO. Q: To get started, who should be on our project team? A: A dedicated team is essential to plan your AI project and drive it forward. To do this successfully, it must have the right members. This includes a committed, executive-level sponsor with the authority to overcome internal obstacles to change. Factory floor supervisors and representatives of the machine operators who will actually implement the AI’s recommendations must also be closely involved. Foundry-wide user compliance with AI recommendations for machine and process settings is absolutely central to success. As a general guideline, compliance rates below 80% make it almost impossible to accurately link the effect of AI recommendations to process outcome — and that breaks the feedback loop that optimization depends on. It is essential that the project team promote AI user adoption. Q: How do I engage our lean team with additional duties? A: Promote success for each operator with giving them independent dashboard control. Run regular project team meetings and update all the operators involved on current results that prove the benefit of compliance with AI prescriptions and what the next set of goals are. Announcing better scrap results, publicizing upcoming training, repeatedly emphasizing the changes required–all these reinforce good behaviors to make them personal and permanent. Give each operator a screen by their machine with their own dashboard that shows the target range of, for example, melt temperature or sand moisture level suggested by the AI. Then operators can pick their own settings required to reach that operating zone. Also, regularly show operators how better control of their own sub-process contributes to overall improvements in scrap. Show that the vision is being realized, thanks to their efforts and publicize the team’s overall contributions. Managers also need reports (again, delivered through simple dashboards) showing compliance rates for each
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