Handling Hazardous Part Variety: Metalcasting as a Case Point

Wadhwa, Rhythm Suren

doi:10.1016/j.procir.2014.02.030

Cited by 2 publications

(2 citation statements)

References 15 publications

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“…One exemplary technical processes, which will benefit from a FEM process optimisation, is the core handling. During the automatic handling, robots and gripper systems are often utilised to transport the foundry cores to the casting mould and to place to cores inside the mould [ 6 ]. In most cases, the gripper has to be specifically designed for this purpose.…”

Section: Introductionmentioning

confidence: 99%

A Plane Stress Failure Criterion for Inorganically-Bound Core Materials

et al. 2021

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Inorganically-bound core materials are used in foundries in high quantities. However, there is no validated mechanical failure criterion, which allows performing finite-element calculations on the core geometries, yet. With finite-element simulations, the cores could be optimised for various production processes from robotic core handling to the decoring process after the casting. To identify a failure criterion, we propose testing methods, that enable us to investigate the fracture behaviour of inorganically-bound core materials. These novel testing methods induce multiple bi-axial stress states into the specimens and are developed for cohesive frictional materials in general and for sand cores in particular. This allows validating failure criteria in principal stress space. We found that a Mohr-Coulomb model describes the fracture of inorganic core materials in a plane stress state quite accurately and adapted it to a failure criterion, which combines the Mohr-Coulomb model with the Weakest-Link theory in one consistent mechanical material model. This novel material model has been successfully utilised to predict the fracture force of a Brazilian test. This prediction is based on the stress fields of a finite element method (FEM) calculation.

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Section: Introductionmentioning

confidence: 99%

A Plane Stress Failure Criterion for Inorganically-Bound Core Materials

et al. 2021

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“…Robots are widely used in industry for positioning, orienting and handling of parts in automated assembly production. Wadhwa (2014) presented the extensive literature review on gripper and proposed design of different grippers to handle the variety of cast part in flexible automated assembly lines. Rooks (1996) reported in his detail case study of foundry automation where the use of gantry and articulated robot of ABB company has been used for handling, loading unloading, palletizing of cores, moulds, pouring and casting.…”

Section: Literature Reviewmentioning

confidence: 99%

Productivity enhancement in investment casting foundry using automation technique in shelling operation

Bansode¹,

Phalle²,

Mantha³

2019

IEJ

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The investment casting industry falls under the highly technological but extremely labor-intensive industry. The increasing need of the complexity, close dimensional accuracy and high reliability of the castings at the most competitive cost has become basic necessity for sustaining growth in the global market place. The purpose of this paper is to study the present manual processes in the Indian investment casting industry and to identify the opportunities to automate them and evaluate its impact on the product quality, productivity and yield which are essential performance parameters for investment casting industry. The approach adopted is to identify and study all the manual processes in the foundry, rejection analysis of a foundry using Pareto analysis followed by cause-effect analysis for defects arising from the manual activities using Ishikawa diagram. Reasoning of shell shop selection for automation and limitation of existing manual layout has been discussed. Process automation using robotics in shell shop uses robot for repetitive dipping, coating and drying cycles on each mould resulted in reducing rejection from 11.2 % to 3.5 %, cycle time reduction from 4-5 days to 2-3 days, improvement in yield from 29 % to 38 % and productivity from 27 % to 32%. Absence of programmer's skills to coat complex geometries to achieve better results is the constraint of the shell automation technique. Higher capital cost restricts the use of robot in wax assembly, foundry shop and post casting operations.

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Handling Hazardous Part Variety: Metalcasting as a Case Point

Cited by 2 publications

References 15 publications

A Plane Stress Failure Criterion for Inorganically-Bound Core Materials

A Plane Stress Failure Criterion for Inorganically-Bound Core Materials

Productivity enhancement in investment casting foundry using automation technique in shelling operation

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