Static Analysis of the Slotted Upper Plate of Low Pressure Casting Machine

Abstract

In this study, the process improvement / Kaizen case study of a casting mold set-up process, was examined. The aim of this work was reducing the set-up time and improving ergonomic conditions. Since existing operating conditions cause a waste of time, an air impact wrench had to be used in the mold assembly process. To be able to use the air impact wrench, a new geometry had to implemented on casting mold and this design change was analyzed in ANSYS software to avoid a failure in working conditions. It was concluded that the maximum stress on the mold was not at a level where it would cause failure. After the initial geometry improvement process, a further ANSYS-Topology optimization process was conducted to reduce weight of the mold. As a result, the set-up time decreased. Consequently, big benefits in terms of cycle time, occupational health and safety, improvement in the process and cost have been achieved.