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Short lead time "patternless" production of prototypes and small batches of small to large castings

Objective



The industrial objective is to meet the competitive needs and expectations of important engineering sectors which depend upon SME foundries supplying 'one-off' or small numbers of castings for the manufacture of original equipment or for the replacement of 'in-service' failures. Their principal requirements are for lower costs and especially reductions in lead time. The technical objective is to satisfy the industry needs by the development of a fast and versatile casting production process, having low operational and capital entry costs for use in SME foundries. It is proposed to eliminate the expensive and time-consuming intermediate stage of pattern and core-box production by the direct cutting of moulds and cores from pre-formed sand compacts using state-of-the-art CAD/CAM and CNC machining technologies. This concept has been assessed in a research feasibility study which identified the further work required. The major tasks include enhancement in CNC machines and post-processor software, developments in cutting tools and machining parameters and optimisation of sand compact processing including minimisation of resin binders and waste sand disposal. SME's specialising in these fields, together with SME foundries and casting users, will be partners in this project. Pre-competitive demonstration of the process in three SME foundries will be a major project task, and a significant contributor to dissemination and post-research commercial exploitation.

Coordinator

Furniss and White Limited
Address
Abbey Way
S31 7JL Un Sheffield
United Kingdom

Participants (12)

ACEROS DEL EBRO S.A.L.
Spain
Address
1,Alejandro Volta 1
50014 Zaragoza
CASTINGS TECHNOLOGY INTERNATIONAL
United Kingdom
Address
East Bank Road 7
S2 3PT Sheffield
Cnc Machining Centres Cms SpA
Italy
Address
Via A. Locatelli 49
24014 Zogno Bergamo
F. Bamford & Co Ltd.
United Kingdom
Address
Whitehill Street
SK4 1NT Stockport
Grenville Consulting (UK) Ltd.
United Kingdom
Address
64,St. Ann's Road 64
CW10 9BY Middlewich
ITT Flygt Products AB
Sweden
Address

361 80 Emmaboda
JC Fabrica de Valvulas S.A.
Spain
Address
219,Avenida Del Carrilet 219
8907 Barcelona
KAMEWA AB
Sweden
Address
5,Varnumsleden 5
681 29 Kristinehamn
Meighs Limited
United Kingdom
Address
Campbell Road
ST4 4ER Stoke On Trent
New Mills Ltd.
United Kingdom
Address
Mill Lane
BT38 9JW Carrickfergus
Oshaug Metal AS
Norway
Address
30,Grandveien 30
6400 Molde
Van Voorden Gieterij B.V.
Netherlands
Address
15,Oude Stationsweg 15
5300 AB Zaltbommel