Reality Check Does the part fit the foundry? Metal Type • Standard grade or unique chemistry? • Would changing to a standard grade meet your requirements?
Reality Check Does the part fit the foundry? Metal Type • Standard grade or unique chemistry? • Would changing to a standard grade meet your requirements? • Could a lower cost material be utilized?
Reality Check Does the part fit the foundry? Metal Type • Standard grade or unique chemistry? • Would changing to a standard grade meet your requirements? • Could a lower cost material be utilized?
Reality Check Does the part fit the foundry? Casting Weight and Size • How well does your casting fit within the foundry’s weight and size parameters? • Being on either end of the spectrum can be costly
Reality Check Does the part fit the foundry? Casting Weight and Size • How well does your casting fit within the foundry’s weight and size parameters? • Being on either end of the spectrum can be costly • Smaller/lighter castings may experience higher levels of scrap due to shakeout damage.
Reality Check Does the part fit the foundry? Casting Weight and Size • How well does your casting fit within the foundry’s weight and size parameters? • Being on either end of the spectrum can be costly • Smaller/lighter castings may experience higher levels of scrap due to shakeout damage. • Larger/heavier castings may require extended cooling time causing a slow down on an automated line.
Reality Check Does the part fit the foundry? Annual Volume • How many pieces do you plan on buying per year? • Small lot sizes can be difficult in a high production foundry.
Reality Check Does the part fit the foundry? Annual Volume • How many pieces do you plan on buying per year? • Small lot sizes can be difficult in a high production foundry. • How many orders per year?
Reality Check Does the part fit the foundry? Annual Volume • How many pieces do you plan on buying per year? • Small lot sizes can be difficult in a high production foundry. • How many orders per year? • Consult with your foundry to determine if your volume is considered low, medium, or high.
Draft angles and finish stock allowance • Draft • Excess draft can add weight • Insufficient draft can increase scrap and rework • Most foundries need 1 to 2 degrees
Draft angles and finish stock allowance • Draft • Excess draft can add weight • Insufficient draft can increase scrap and rework • Most foundries need 1 to 2 degrees
• Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases machining costs • Insufficient stock can shorten insert life and increase scrap due to tool breakage and non clean-up
Parting lines • Flat, straight partings lines are a best practice • Offset parting lines are common, but… • Can increase pattern cost • Are more likely to produce parting fins • Can cause mold compaction issues
Parting lines • Flat, straight partings lines are a best practice • Offset parting lines are common, but… • Can increase pattern cost • Are more likely to produce parting fins • Can cause mold compaction issues
• Can you minimize the effect of the parting line?
Parting lines • Flat, straight partings lines are a best practice • Offset parting lines are common, but… • Can increase pattern cost • Are more likely to produce parting fins • Can cause mold compaction issues
• Can you minimize the effect of the parting line?
Cores • Look for ways to minimize or eliminate cores • Can you incorporate several cores into one? • Be aware of the assembly cost • Make sure the assembly is robust
Cores • Look for ways to minimize or eliminate cores • Can you incorporate several cores into one? • Be aware of the assembly cost • Make sure the assembly is robust