castings

[Programinator]

My boss and i are thinking about getting some casting work but we do not have much experience with it. some feedback of the pros and cons would be nice. Thanks

[Ployd]

Is it going to be mass production or a few small runs?

 

You will need some fixtures set up.

 

Plus depending on the casting quality and foundry you may end up cutting something that gets scrapped. You need to be able to check the castings before you spend the time to cut them. Set up some reference points to check the casting prior to cutting.

[Ployd]

Oh, and another point is the castings are only as good as the patterns used to make them. So you may want to find out what the scrap percentage will be on your end.

 

When I worked with Powermatic they had four patterns that were all slightly different. Made machining difficult.

[Thee Rickster ™]

Our shop produces our own molds and we pour

all-356 and za-12. we also machine 99% of our

castings.

 

+1 Ployd

 

Castings can be inconsistent and straightening

to points in a straightening fixture is common,

prior to machining them in a production fixture.

(depending on structure and rigidity)

 

Some times you will get a different inconsistency

from one run to another. Ultimately implementing

a system of controls and protocols will reduce

scrap rates and increase repeatability.

 

I suggest you have an a couple of personnel in

your QA department experienced in checking

machined castings.

 

HTH

[Ployd]

Yup, just make sure you know exactly what your getting into. Trying something new is how you learn.

[BernieT]

+100 to all above...

 

No two castings are the same, holding fixtures are key to success. Fixturing is supposed to be off 'tooling points' which can sometimes be nearly impossible. Having an experienced person can really help.

 

Lots of shops successfully machine castings but it is a learning experience. It will take time and experience to get comfortable doing so.

 

Go slow to start and work into it.

 

Be careful of the liability of scrapping an expensive casting.

 

Make sure you know the inspection requirements before taking the order.

 

Good luck!!!!

[Programinator]

thanks for the input guys. We are a small shop and a huge oportunity is in front of us to take on large quantities of casting work. We have shop floor space available to bring in any machines we need but like i said i have limited experience in castings. So from what you all tell me i should put much thought and inspection in before even making chips.

 

 

how do the cnc's like cutting casting??

[chris m]

What material are you looking at?

 

C

[Programinator]

not sure yet but i will let you know when i find out