Green Sand Metalcasting Foundry News

Cloud-based software promises to reduce green sand casting rejects and optimize additive consumption by applying predictive and prescriptive data analytics, machine learning and IoT functions to green-sand molding

Excerpt from the March 2019 issue of Foundry Management & Technology

The Smart factory "vision" is gaining global acceptance. It involves integrating data analytics, machine learning and IoT by incorporating sensors, SCADA and line-speed or near-real-time data-based analytics for process optimization. Predictive and prescriptive data decision-support, predicting highly accurate outcome has shifted the paradigm in manufacturing and many other industrial and consumer sectors. For manufacturers, rapid proliferation and advancement of information technologies, such as cloud computing, allows them to generate and store huge volumes of data.

In addition, the digitalization of the green sand casting process automation has empowered industries to collect and transmit near-real-time data. Cloud computing ensures data availability without geographic or physical limitations. By leveraging the power of data-based analytics and machine learning, industries are generating significant tangible and intangible profits.

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Todays foundries cannot afford to sacrifice the efficiency and profits that are the consequences of poorly controlled hot molding sand.

Excerpt from the June 2003 issue of Foundry Management & Technology

Metalcasting researchers say hot sand is the leading sand-related problem for today’s foundries. Most metalcasters recognize a relationship between reduced casting quality, increased process variation, and other molding inefficiencies that result from using hot molding sands. Studies show that hot sand affects virtually every operation in the production line.

System sand returned to the muller for reconditioning with a temperature of 160°F (approximately 70°C) or greater is considered to be excessively hot. Return sand ranging from 120° to 160°F (approx. 49°-70°C) is hot enough to demonstrate inconsistent properties during mixing and to be very difficult to control.

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Excerpt from the October 2013 issue of Foundry Management & Technology by Mark Riekert and John Kuhn

Robotic sand core setting into a mold has the potential to increase molding productivity and reduce casting scrap.

With the evolution of casting designs, driven by requirements for lower-weight parts and (in automotive applications) a desire to minimize assemblies, there follow designs with thinner walls and smaller openings/cavities.  These structures need cores to create those thin wall sections, and in some examples these walls are as thin as 4 mm.  In addition, small cores are used to create small openings and cavities. 

Adding to the difficulty of the arrangement, gripping the core was a very specific challenge. The end-of-arm tool (EOAT) or end effector uses a rubber "squash" ring to expand inside a hole in the core, and a parallel gripper to contain the tail section of the core without actually gripping it. The core was specially designed with a hole to allow the tool to grip it.

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Originally published in the May 2017 issue of Foundry Management & Technology.

by Alexander Brown

Controlling raw materials is critical to the success of iron casting production from green sand systems. The base silica sand is often overlooked, with the main focus on bentonite additions. Carbonaceous additives can be considered a “necessary evil” to ensure a good surface finish and reduction in sand-related surface defects. Other additives are used when systems get out of balance, and these will further complicate the complexity of green sand systems.

For castings requiring cores, this becomes a bigger issue, as many different resin systems are employed for core production, and these must be taken into consideration when controlling both the carbonaceous levels and the overall grading of the sand system. The twin effects on additional carbon and loss-on-ignition and overall sand grading need careful understanding and control.

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North American foundry and diecasting managers and decision makers give the final word on industry conditions today — and the first word on their expectations for metalcasting growth and development in the coming year.

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