Simple Solutions That Work! Issue 9

Contact: TROY TURNBULL [email protected] BACK-2-BASICS MINOR CHANGES: BIG RESULTS Real life applications illustrate how mechanical systems deliver big improvements. In one instance, an automotive supplier, running five casting machines, experienced scrap due to inconsistency in lube dilution. Most days the mixture was too rich, causing staining and build-up on the cavity surface. Conversely, when the dilution was too lean it resulted in stuck or bent castings. By installing a Pro-Mix proportioning system, they were able to achieve spot-on dilution ratios, reducing lube variability and scrap rates caused by improper dilution by up to 20 percent. Even more dramatic are the results from a casting company that was hand mixing die lubricant from 300 gallon totes. Operators would haul 5-gallon pails to the tote of lubricant, and then lug them back the casting. If there is too much lubricant, it may not evaporate fast enough as the molten metal is being injected, causing porosity in the castings. Complicating these issues is the human inconsistency factor. Each shift might have its own methodology for applying lubricant. Adjustments in the automation for positions and speeds, as well as individual tweaking at each applicator, is often modified shift to shift, resulting in quality variations and production delays. As with mixing, lube consistency is best achieved through an automated system with adjustability so that hot areas can receive intense spraying while low temp areas receive less spray. Optimal spraying with the proper dilution ratio, right manifold, spray heads, and nozzles will reduce cycle time, labor and scrap. This starts by selecting a reciprocating die spray system that can quickly and accurately guide the spray manifold into the die area. We recommend servo- controlled systems, which achieve pinpoint accuracy and stop and spray at multiple positions at different pre-determined times, helping to prevent non-fill, solder and porosity issues. You also want a system that offers adjustable spray patterns and volumes. The next step is selecting the spraying package. As the most time-consuming part of the total casting cycle, manifold selection is more important than people realize. Because there are many possible combinations of spray manifolds, it’s advisable to consult with your supplier so you maximize your reciprocator’s spray effectiveness. to the machines throughout the plant. This caused unwarranted downtime, housekeeping issues and potential safety hazards. Additionally, hand mixing meant the lubricant was not properly blended, causing inconsistent mixtures, clumping and waste. Installation of a central lubrication system to consistently mix and deliver lube direct to the equipment resulted in an estimated 70 percent reduction in waste. If you’re experiencing issues in your casting process or looking for ways to improve productivity and reduce waste, they might be solved simply by building consistency into the way you manage, blend and apply your lubricant. 21