Effort Foundry Inc. Technology is the buzzword heard around the foundry today
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1 Effort Foundry Inc Technology is the buzzword heard around the foundry today
2 NEW TECHNOLOGY OVERVIEW EFFORT FOUNDRY IS MAKING HUGE INVESTMENTS INTO NEW TECHNOLOGY AS A PART OF OUR CONTINUOUS IMPROVEMENT PROGRAM TO BETTER SERVE OUR CUSTOMERS PRECISION MACHINING SOLID MODELING MACHINING SIMULATION 3D LASER SCANNING SOLIDIFICATION SIMULATION LASER MARKING ADDITIVE MANUFACTURING 3D printing is currently outsourced with plans in place for it to be added to in-house capability
3 IN-HOUSE MACHINING TECHNOLOGY OVERVIEW VERTICAL TURNING HORIZONTAL TURNING HORIZONTAL MILLING VERTICAL MILLING KEYWAY CUTTER COMPETENCIES ROUGH MACHINING CASTINGS FINISH MACHINING CASTINGS PATTERNS AND PATTERN COMPONENTS BENEFITS VALIDATE CASTING QUALITY LOCATE AND UPGRADE SHRINK, INCLUSIONS, CRACKS, ECT VALUE ADDED SERVICE TO CUSTOMER ONE STOP SUPPLIER DELIVERY FASTER REACTION TIME MACHINING ON CUSTOMERS SCHEDULE
4 VERTICAL TURNING WITH MILLING ROUGH & FINISH MACHINING PART DIAMETERS UP TO 40 PART LENGTHS TO 35 MILLING ON TOP AND SIDE TOLERANCES TO.0002 AUTOMATIC TOOL CHANGER
5 VERTICAL TURNING WITH MILLING TURNING MILLING DRILLING TAPPING TOP FEATURES SIDE FEATURES
6 HORIZONTAL MILLING ROUGH & FINISH MACHINING (2) ROTARY DEVICES FULL 5 AXIS X TRAVEL 40 Y TRAVEL 30 Z TRAVEL 25 TOLERANCES TO.0002 AUTOMATIC TOOL CHANGER
7 HORIZONTAL MILLING MILLING DRILLING TAPPING MACHINING ON 5 SIDES IN ONE HOLDING
8 VERTICAL MILLING ROUGH & FINISH MACHINING X TRAVEL 30 Y TRAVEL 20 Z TRAVEL 20 TOLERANCES TO.0002 AUTOMATIC TOOL CHANGER
9 VERTICAL MILLING MILLING DRILLING TAPPING
10 HORIZONTAL TURNING ROUGH & FINISH MACHINING PART DIAMETERS UP TO 40 PART LENGTHS TO 60 MILLING ON FRONT AND SIDE TOLERANCES TO.0002 AUTOMATIC TOOL CHANGER
11 HORIZONTAL TURNING TURNING MILLING DRILLING TAPPING FRONT FEATURES SIDE FEATURES
12 KEYSEATER KEYWAYS FROM 1/16 TO 1-1/2 WIDE UP TO 12 LONG
13 Solid Modeling and Simulation Technology Flowchart 3D Model Parts from 2D CAM Create Machine Tool G-Code Rough and Finish Machining of Castings Machining of New Patterns SolidWorks Solidification Simulation Verify Casting Process Verify Heat Treat Process Verify Material Stress 3D Model Patterns from 2D 3D Printed Plastic Complex Pattern Components Complete Patterns
14 3D Scanning Technology Flowchart Scan Pattern Solidworks Inspect Pattern Assemble 3D Mold Dimensional Reporting Solidification Simulation 3D Scanner Inspect Casting Dimensional Reporting Scan Casting Solidworks 3D Model Casting CAM ESPRIT
15 Laser Marking Technology Flowchart Rough Machined Customer Permanent Part Identification Completely Customizable Per Customer Requirements Laser Marker Effort Foundry In-house Part Verification Part # Heat # Pattern # Material Finish Machined EFI Vendor Part ID for Outside Processing Part # Heat # Pattern # Material
16 Additive Manufacturing (3D Printing) Technology Flowchart 3D printing is currently outsourced with plans in place for it to be added to in-house capability Plastic Patterns Complex Geometry 3D Printed Complete Patterns 3D Printed Pattern Components 3D Printing Sand Molds & Cores Complex Geometry 3D Printed Molds & Cores Metal Currently In Research & Development Dept Complete Parts Complex Geometry 3D Printed Parts
17 Ready to Mold Measure Pattern 3D Scan Model in Solidworks Import to ProCast Simulate Pass Fail Modify Model in Solidworks
18 3D Scanning
19 3D Scanning For Inspection
20 3D Printing In Effort Foundry
21 Ready to Mold Model Casting in Solidworks Model Rigging in Solidworks Import to ProCast Simulate Pass Fail Modify Model in Solidworks
22 Model Finished Machined Part in Solidworks Model Adding.06 to Finished Surfaces Model the As-Cast for Material Removal In-house Drawings made and checked Create Toolpath for Rough and Finish Ready for Machine Shop
23 Model Finished Machined Part in Solidworks
24 Model Adding.06 to Finished Surfaces
25 Model the As-Cast for Material Removal
26 In-house Drawings made and checked
27 Create Toolpath for Rough and Finish
28 Validate Casting Baseline Rough Machine to Drawing NDT and Upgrade Finish Machining Required? Yes Finish Machine to Drawing No Ready to Ship Final Dimensional Verification
29 Validate Casting Baseline
30 Rough Machine to Drawing
31 Finish Machine to Drawing
32 Patterns Too!
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