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Old 11-08-2011, 06:31 PM   #46
mopar_mark
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Default Re: making A 671 Blower

Thanks for posting & going into great detail, some of the terminology doesn't make sense, but the pictures do after a few looks. I was just used to receiving castings & machining, I never realised or gave it a thought, the amount of work that goes into pattern making.
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Old 11-09-2011, 01:07 PM   #47
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Default Re: making A 671 Blower

Day 20:



Took the pattern over to the foundry today, setting up the cope(top) side of the pattern and getting the flask pin holes drilled out, should be ready to mold and cast tomorrow. Ill have more photos up of today later on.

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haulin' flask



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Tough filling the corners of the leather fillets before painting




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Drag(bottom) side of the pattern Painted and ready to go





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Taking the pattern over to the foundry



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Bringing some wood along too



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Place where we prep all of our patterns, this is the same place where i build the corebox and pattern in my other video of the hammer. http://www.youtube.com/watch?v=VOSOG3MNmxI



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Leather filleting the cope(top) side of the pattern



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done



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Our 70 ton sand hopper for our green sand lines.




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Line 3 of our molding stations, this is where we will start out making the blower molds, the pattern will be hand drawn by 2 people for now.



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If production increases on the blowers though the pattern will be ran on line 4, which will all be lifted and moved by a machine, allowing only one person to make the mold.



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four 2000 pound furnaces filled with 1400F molten aluminum. we also have an overhead crane that lifts a 3000lb tilter to refill our furnaces for when we run extreme high production.



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Pouring deck, the molds are placed on pallets and pushed across the deck for the deck guys to pour the metal, temperatures can reach up to 120F in the summer time here.



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These are our tilts that drop the molds and castings into the shakeout trough, the pallets slide underneath the deck and roll make to the molding stations(not a fun jobs to fix if you screw up and get one stuck under the deck ). The castings are pulled out of the sand and the sand runs down the trough and up a conveyor belt to the top of the 70 hopper, and the process repeats.

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Old 11-09-2011, 04:31 PM   #48
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Default Re: making A 671 Blower

Thank you very much for posting this..
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Old 11-09-2011, 05:12 PM   #49
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Default Re: making A 671 Blower

Day 20.2:

end of the day photos for day 20. If everything works out correctly, I should have a casting in my hand tomorrow .

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Intake adapter plate sitting on top of the blower pattern(its sitting on the pins about 2" off the plate, that is why it looks off)



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Mounted the adapter plate to the pattern board.



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Red pattern paint for the Risers and pattern cope(top)




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Making more cores, hollowing them out with a die grinder, this makes it easier to break up the cores in knockout






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How not to hollow out a core



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Glued together and ready to be placed in the mold.

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Old 11-10-2011, 07:03 AM   #50
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Default Re: making A 671 Blower

.. and you get paid to have fun?
messed up.
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Old 11-10-2011, 07:58 AM   #51
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Default Re: making A 671 Blower

Quote:
Originally Posted by 1970ls8 View Post
.. and you get paid to have fun?
messed up.
lol, well put. Its not always fun and games though
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Old 11-10-2011, 08:06 AM   #52
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Default Re: making A 671 Blower

... yeah. some times you have to bring your own lunch; bummer
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Old 11-10-2011, 01:11 PM   #53
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Default Re: making A 671 Blower

Day 21:

well i was put on hold today for molding the blower, we have to run another job that needs to get done. Will be molding tomorrow, good news though that the intake adapter plate pattern will be ready to mold tomorrow too.

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Our pattern for our 100 series grenade shift knobs i saw sitting on a rack, figured id take a picture of it, you can check those out at http://www.diamondp.com/category_s/128.htm



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cope basin drilled and screwed down, pin for the down sprue through it.



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Outline of the flask, you can also see a hole punched and the bottom of the picture for the flask pin hole location



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punched location for the flask pin hole



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Laying out the mold buttons(used to locate and hold the mold in place



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Setting the pattern up on the press



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centering the cutter for the flask pin holes



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Flask pin holes cut out



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Pattern button, and the cutter used to make the opposite indention in the plate.



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Cutting the indention of the buttons, the buttons will be mounted on the other side of the pattern



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buttons mounted, flask pin holes cut, down sprue basins mounted, only a few more things to do



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Intake adapter mounted with gating



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Cope



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Leather Fillets all done



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Pattern sat down on the flask drag(bottom)



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Cope(top) sat down on the pattern



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These are the flask pins i was talking about, they are the guides for pulling the cope and pattern off the drag, this prevents the molder from tilting the mold, there is still room for human error, but this greatly reduces it

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Old 11-10-2011, 01:38 PM   #54
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Default Re: making A 671 Blower

Im really enjoying following this thread. Keep up the great work and Pics!!!!!!!!!
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Old 11-10-2011, 05:29 PM   #55
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Default Re: making A 671 Blower

Day 21.2:

Pattern is completely done, ready to mold tomorrow, we set up the flask on molding station 3 but it is to large to spin so we are going to set it up on line 4 tomorrow, luck we did it before we left or we would be spending 2 hours extra tomorrow getting it set up.

i also took a video of our CAM software simulating the CNC cutting of our rotors, ill upload it and hopefully post it in an hour or two.

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tough filled



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Down sprue put in



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Risers cut and ground with pads, bolting them down tomorrow, then painted and the pattern should be ready to mold.



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1/4" holes drilled out for the pins



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grinded the edges of the pattern down so the flask latches could have more clearance, but its not enough...



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So we improvise



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Better



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These latches work by a cam, as you twist them the tighten up and close the flask, this way when the machine squeezes the sand, u just release the latches and are able to easily pull the flask off the mold.

open



Closed



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Open(gap between the plates, foam is in between them)



Closed



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Risers sitting inside



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Squeeze board being cut to allow it to not crush the riser boards when the sand is compacted



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Flask being setup and aligned in the molding machine, its not going to fit though so we will be moving it to line 4.



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arms that will lift up and allow the molder to spin the flask around to squeeze the cope and drag.




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Jaws or teeth, used to clamp onto the cope to pull it off the mold, so that the molder can pull the pattern and set the cores in the mold.

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Old 11-10-2011, 05:59 PM   #56
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Default Re: making A 671 Blower

I think I grossly under estimated this blower build. My bad. This is extremely interesting.
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Old 11-11-2011, 10:38 AM   #57
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Default Re: making A 671 Blower

Pretty amazing stuff, I had no clue it took all that to make a casting. I don't quite follow it all, but once I see the casting I think it will all tie together for me.
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Old 11-11-2011, 02:22 PM   #58
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Default Re: making A 671 Blower

Day 22: Casting

Lot of photos today, had a few problems molding but we've sorted it out, have the casting ban sawed and ready to be taken to the cleaning room. You will see this in the photos but we are going to be pouring these cases with X-ray quality metal, we've degassed our metal twice and will be sending one of our cases to X-ray and for lab testing. To give you an idea though, we just got back our lab results of some castings we did last week that where also X-ray quality, there tensile strength was around 33,000-35,000. I will have photos up of the results when we get them and pictures of the x-rays. which will all be in the video too.

Still can't get youtube to upload my rotor video.

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liquid parting line being sprayed on the flask and pattern



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Sand being dropped down into the flask



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Ramming the sand with a air rammer



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Bottom board being placed



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Squeezing, not positive but i believe this machine squeeze above 120psi



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rolling over to mold cope



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Liquid parting on the cope side



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Ramming the sand



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Ramming tools



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squeeze board




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Mold being squeezed, we squeeze once, fill with sand again and squeeze, or just called double squeezing



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Compressed over 2", hard as a rock, i punched it and didn't even leave a dent



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Squeeze board off, you can see the risers sticking out



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The second squeeze



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Old 11-11-2011, 02:23 PM   #59
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Default Re: making A 671 Blower

Day 22.3: Casting

cooling the sample off in our high tech low pressure submersible cooling machine



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Cutting the sample



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Sample one, we where not happen with this so we ran another degas cycle. It is hard to see in the photos but there are minute bubbles in the metal, again, exaggerated from the zero pressure test. They would not be visible by the human eye if cooled normally.







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Sample two is on the left and we are good to pour now, the other sample is from another furnace found a while back, i just wanted to show a bad sample with a good.



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Mold being slide down the line



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2000lb furnace, about 1000lb in it now



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The far ladle is 55lb of metal, the closer one is 35lbs of metal



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Filling up the mold




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Thats all that is left off the 55lb, 35lb was empty



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Mold being dumped into the shakeout trough





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Being hooked up to the crane



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Old 11-11-2011, 02:23 PM   #60
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Default Re: making A 671 Blower

Day 22.4: Casting

Taken to the scales and weighed with the core still in it. 136lbs





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Sitting outside to cool down before knockout




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We have been testing a new chemical for our airset that is a 50/50 blend, it works so well that we didn't even have to hook up the casting to the knock out, it just feel apart with a few hammer hits. And this core was actually not hollowed out, it is pure solid sand.






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Band sawed and weighed, 47lbs, this will be a little less once it is ground and machined to size





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This machine is the knockout machine, which works by clamping jaws down to the risers and ramming them extremely fast and vibrating the core apart, we just brought it in here though to blow it off with some air to see the casting better.

These photos are of the very first casting off the line. We like to do it right the first time , this will also be the one X-rayed and tested. It is still a little dirty but once it is ground and ran through the shot blast machine it will look awesome.









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Thats it for now, i will try to get the case ground and shot blast so you can see it cleaned up a bit, but i have a wedding rehearsal to be at in a few hours so we will see. Ill probably go in sat our sun to work on it a bit and get a few more photos and get the video up as fast as i can
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