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Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Exploitable results
The production of controllable pitch propellers is currently undertaken using a conventional pattern manufacture, mould and casting production. The process is usually limited to a small series production made to order and for a specific vessel. The process of blade manufacture is very often under time and cost constraints. The production of blade series using a machines sand compact has been developed which can provide highly accurate moulds and blade castings without the need for a pattern. The process provides capabilities to produce close to size castings which together with the absence of a pattern can yield cost and time savings in the production cycle.
The benefits obtained form the process depend upon the background and developed manufacturing technology of Oshaug Metall.
Provide an overview of the result which gives the reader an immediate impression of the nature of the result, its relevance and its potential; Briefly describe the current status/applications of the result (if appropriate) with non confidential information on entities potentially involved.
The production of fixed pitch propellers is currently carried out using mainly a hand moulded technique with a high and experienced labour content. The ability to manufacture fixed pitch propeller blades by a process which employs data taken directly as a 3D model, or as 2D and modelled, and to be able to directly use this to manufacture a sand mould by CNC machining allows precise dimensions to be achieved. When this activity is used with a manufacturing technique developed from the conventional process, a new capability can be offered by which fixed pitch propellers of near net shape can be made giving cost and time savings over the conventional method. Such a process has been developed and is being used for high accuracy and high quality blade manufacture by project partners.
The process depends on the background and developed technology of Van Voorden Gieterij B.V.
A system for the high speed machining of sand compacts has been designed and developed. This system includes a high speed CNC machine fitted with a moveable mould support plate. The plate carries the sand compact and can be moved in and out of the CNC machine working envelope to allow additional work to be carried out on the sand mould. The system also includes tooling and software specifically designed to cater for the sand machining process.
The manufacture of sand moulds by this technique can use CAD data directly to produce shaped moulds for casting without the need to produce a pattern. The process can manufacture prototypes and small series production and offers benefits in the time to manufacture a mould, the cost and the quality when compared to conventional prototype and small batch manufacture.
The system is suited for the SME foundry industry and casting user group, particularly where one off castings or small series castings are required. It provides a capability to produce prototype castings without the costly need for pattern manufacture.
A facility and system has been developed and is in place at CDC for the manufacture of protoype and small series castings using the direct machining of sand compacts where no pattern is required. The facility comprises of capabilities to input data in all forms from 2 dimensional conventional drawings to 3 dimensional CAD files. These can be reviewed and manipulated to prepare cutter paths and with a manufacturing strategy consistent with the form and quality of the end cast product. The manufacture of the moulds is by the optimum cost and time effective manner including the direct machining of sand compacts and other means.
The facility allows prototype and small series castings to be manufactured as a one stop operation from drawing details to finished, tested and inspected castings.
The manufacture of castings by the direct machining of sand compacts using a CNC machine and data from CAD information has been developed and allows production of metal parts without the need for pattern manufacture. This process can provide prototype and small series casting manufacture in a cost and time efficient manner.
The process relies on the developed technologies which are specific to the mould production by machining sand. The strategies of manufacture together with the sand compact production and methodologies can provide benefits in the cost and timescale for part manufacture.
The process is currently available with a manufacturing unit located at the CDC in Sheffield.
A PC based software has been developed for the control and input of data from a CAD system into a CNC machine controller. The software has been specifically based on the requirements for the direct machining of sand compacts using a CNC machine. These sand compacts are used for casting manufacture and the process does not rely on the production of pattern equipment.
The software has the capabilities to:
- displays a 3 d model of the component
- shows the datum locations and x,y,z directions over a wire frame picture
- holds and lists the NC programmes sent from the CAD system
- provides a text window the input data relevant to the manufacturing process
- allows the programmes to be sent to the machine controller on a selected basis
- provides a link to use the Metacut machine optimization software programme
- Other functionalities can be provided as required for each application. The software has been developed by Grenville Consulting(UK) Ltd.
The manipulator and mould support plate have been designed and developed to be capable of moving sand compacts of weights up to 10,000kgs and locating accurately within a CNC machine tool working envelope. The development has been undertaken together with the machine tool manufacture for a specific process of machining sand compacts used as moulds in metal casting.
The manipulator operates the lifting and moving of the mould support plate which carries the sand compact. Movement is along small rails which are constructed to allow movement into and out of the machine tool area. The rails are able to be removed from outside the machine tool to allow a clear access with an uninterrupted roadway. The mould support plate has been constructed with locating pins designed to allow indexing of the plate if required.
The design is currently available and can be tailored for any machine tool configuration.
The machining of sand by a CNC process represents a new venture for the machine tool industry. The cutting practices and tooling types used for this process have been developed to provide a full range of capabilities for the CNC machine tool when producing moulds made by the sand machining process.
Specific capabilities were necessary for the machining of sand and these have been addressed and the tooling range of Plansee UK Ltd. extended to include these requirements. Tool extensions of up to 400mm have been produced and these can be fitted with suitable grades of insert cutters.
These are currently available and can be supplied together with the sand machining system
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