Waukesha Foundry

Metal Casting Process Simulation

Process Flow Diagrams

Mark Polczynski, PhD Marquette University mark.polczynski@marquette.edu
Waukesha Foundry - Process Flow Diagram 1

Simulation Modeling Process Map
1. 2. 3. 4. Project Overview: Project goal and general approach. System Description: Text narrative derived from initial interviews. Context Diagram: Scope and boundaries of model. Data Flow Diagram: Movement of data and materials.

5.
6. 7.

State Transition Diagrams: Transitions between system wait states.
Entity Relationship Diagram: Interactions between system elements. Process Flow Diagrams: Decisions controlling system behavior.

8.
9.

Causal Loop Diagram: System cause and effect relationships.
IBIS Analysis: Description of “fuzzy” decisions.

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10. Simulation Model: Patient movement and resource utilization.

Waukesha Foundry - Process Flow Diagram

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Process Flow Diagrams
• • • Process flow diagrams provide detailed descriptions of each process shown in the data flow diagrams for a system. This presentation provides the process flow diagrams for the casting process data flow diagrams. The data flow diagram associated with each process flow diagram is shown for reference.

Waukesha Foundry - Process Flow Diagram

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Start

1.1 Prepare sand
Note: Same process used to prepare mold sand and core sand

Determine sand, binder, additive amounts

New sand

Reclaimed sand

Additives

Binder part 1

Catalyst

Binder part 2

Fill new sand hopper

Fill recalimed sand hopper

Fill additives hopper

Fill binder part 1 hopper

Fill cayalyst hopper

Fill binder part 2 hopper

Add new sand reclaimed sand, additives to augur

Add binder part 1 to augur

Add binder catalyst to augur

Add binder part 2 to augur

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Patterns Sand binders New sand Reclaimed sand 1.1 Prepare sand Blended sand 1.2 Prepare mold* Cope, drag, cores 1.3 Assemble mold Assembled mold
Adjust amount of sand components N Sand blend acceptable? Y Blended sand End

Waukesha Foundry - Process Flow Diagram

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Start

1.2 Prepare mold
Process is similar for cope, drag, and cores Patterns Blended sand

Clean frame

Place pattern into frame

Place inserts into frame

Pour blended sand into frame and vibrate

Remove inserts and strike mold

Wait ~5 min. for sand mixture to surface cure

Flip and remove mold from frame

Clean up mold

Spray mold with coating

Dry coating in oven

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Patterns Sand binders New sand Reclaimed sand 1.1 Prepare sand Blended sand 1.2 Prepare mold* Cope, drag, cores 1.3 Assemble mold

Cope, drag, cores

End

Assembled mold

Waukesha Foundry - Process Flow Diagram

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Start

1.3 Assemble mold
Cope, drag, cores

Apply glue to mold components

Align mold

Close mold

Open mold

Adjust mold

N

Mold aligned?

Y

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Patterns Sand binders New sand Reclaimed sand 1.1 Prepare sand Blended sand 1.2 Prepare mold* Cope, drag, cores

Close mold

Add pouring cup and cover openings Assembled mold

Wait for full cure of mold

1.3 Assemble mold

Assembled mold

End

Waukesha Foundry - Process Flow Diagram

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Start

2.1 Prepare alloy

Pure metal

Clean/patch furnace

Reclaimed metal Pre-heat furnace Scrap metal

Determine metal components amounts

Weigh metal component amounts

Load furnace

Melt metal components

Metal melt acceptable?

Y

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Pure metal Scrap metal 2.1 Prepare alloy Assembled mold 2.2 Cast part 2.3 Finish part Used sand

N

Metal alloy

End
Metal alloy Cast parts Finished parts

Reclaimed metal

Waukesha Foundry - Process Flow Diagram

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Start

Metal alloy

Assembled mold

2.2 Cast part

Clean/patch ladel

Pre-heat ladel

Fill ladel

Pour metal

Cool part

Break mold

Remove part

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Pure metal Scrap metal 2.1 Prepare alloy Assembled mold 2.2 Cast part 2.3 Finish part Used sand

Cast part

Used sand

End

Metal alloy

Cast parts

Finished parts

Reclaimed metal

Waukesha Foundry - Process Flow Diagram

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Start Cast part Reclaimed metal

2.3 Finish part

Shot blast part

Cut/burn off excess material

Grind part to shape

Heat treat?

Y

Send out to heat treat

N

Steel shot blast part

Good part?

N

Rework?

N

Reclaim metal

Y

Y

Reclaimed metal

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Rework defects

Send part to shipping Finished parts

Pure metal Scrap metal 2.1 Prepare alloy

Assembled mold 2.2 Cast part 2.3 Finish part

Used sand

Metal alloy

Cast parts

Finished parts

End

Reclaimed metal

Waukesha Foundry - Process Flow Diagram

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Start

3. Reclaim sand
Used sand

Crush mold

Remove binder and fines

Proper sand consistency ?

N

Dispose of bad sand

Y

Reclaimed sand

Patterns Sand binders New sand 1. Build mold Assembled mold 2. Cast part

Pure metal Scrap metal Finished parts Reclaimed sand 3. Reclaim sand Used sand

End

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Waukesha Foundry - Process Flow Diagram