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Technologies
Opened in 1996.
Specializes in prototypes &
low volume production
runs.
TS Certified 16949.
Dualtech, Inc.
Ductile/Aluminum Casting Technology
Opened in 2002.
Prototyping and low volume production.
Metals
TS 16949 Certified.
Pattern Shop
Cope
Cope
Parting Line
Drag
1. File Preparation
Drag
Pattern Shop
1. File Preparation
Pattern Shop
Drag The bottom half or the part that drags on the floor.
1. File Preparation
Pattern Shop
1. File Preparation
Pattern Shop
Pattern Shop
1. File Preparation
Pattern Shop
1. File Preparation
Pattern Shop
1. File Preparation
Pattern Shop
Cope
Parting Line
Drag
Parting Line
Drag
Body Core Needed
Parting Line
1. File Preparation
Pattern Shop
Pattern Shop
Pattern Shop
Tooling
Standard 4 inch face mill.
1 inch flat bottom mill.
1/2 inch flat bottom mill.
Pattern Shop
Tooling
1/8 inch ball end mill.
1/4 inch ball end mill.
1/2 inch ball end mill.
Pattern Shop
Pattern Shop
All tool paths are then processed into alpha and numeric
code.
G Code
Pattern Shop
Pattern Shop
Pattern Shop
Pattern Shop
Notes
Rib intersections.
Use offsets if possible to avoid porosity and voids.
Bad
Notes
Good
Incorrect
Notes
Correct
Sharp Corners
Local
Structural
Weakness
(possible
hot tear)
Notes
Shrink
Defect
Radius to the
outsider corner
equals 20.
Notes
Incorrect
Notes
Correct
Incorrect
Notes
Correct
Incorrect
Better
Improved
Best
Notes
2 in.
Notes
1 in.
Cope
Parting Line
Drag
Notes
Cope
Parting Line
Drag
Notes
Step 3: Casting
Process
1. Molding
2. Melting
3. Pouring
4. Shakeout
5. Cutoff & Grinding
Dualtech, Inc.
Ductile/Aluminum Casting Technology
Opened in 2002.
Prototyping and low volume production.
Metals
TS 16949 Certified
Casting
Types of Foundries
Casting
Casting
Robert Sintos
Hunter
Casting
1. Molding
Casting
1. Molding
Casting
1. Molding
Casting
1. Molding
Casting
Core is blown.
Chamber is filled with sand, air then blows the sand into the core box.
Efficient for small-mid sized cores.
1. Molding
Casting
1. Molding
Casting
1. Molding
Casting
1. Molding
Casting
1. Molding
Casting
Ready to close.
1. Molding
Casting
After the cope and drag halves are assembled, the mold
is closed using a crane.
Smaller molds are closed by hand.
1. Molding
Casting
Metals Poured.
Aluminum 356, 355, 319, etc.
Iron Gray, Ductile, Ni-resist.
Recipe is prepared by callouts per spec.
Cummins spec 40,000.
2. Melting
Casting
Nickel
Silicon
2. Melting
Molybdenum
Copper
2. Melting
Casting
2. Melting
Casting
2. Melting
Casting
3. Pouring
Casting
Aluminum Pouring.
3. Pouring
Casting
3. Pouring
Casting
Choked Runner
3. Pouring
Casting
The metal then drops through the filter to the drag half.
3. Pouring
Casting
Runner
3. Pouring
Casting
Hot Riser
3. Pouring
Casting
3. Pouring
Casting
Vents
Cold Riser
3. Pouring
Casting
Casting
3. Pouring
Casting
4. Shakeout
Casting
The machine shakes the mold until the sand has broken
away from the part so it can be removed.
The shaker continues to shake until the sand has returned
to normal size so it can be reclaimed for future molds.
4. Shakeout
Casting
Casting
Machine Shop
When the casting layout is confirmed, the casting is given the OK to be
machined.
After the casting is given the OK, a router is given to the machinist.
The router contains all pertinent information necessary to machine the
part.
(Router example on next page)
Machining
Job #
Customer
Phone #
Quantity
Comments:
9057
Cummins
843-745-1602
40
Part #
Contact
Fax #
3924561
Greg Wright
Received Date
2/2/2009
Desc.
Manifold
Mach Req.
Yes
Heat Treat
No
Delivery Date
2/2/2009
Pattern Shop
Start Date
Shrink
Comments
N/A
Finish Date
Draft
#Core boxes
Design reviewed
Foundry
Material
40000
Poured #
33
Casting Wt #
13 lbs
# Core Boxes
2
Comments
25 pore filter - Tits are fragile on cores (4x) - Pour temp 2580 degrees - 9 sec pour time Blow cores and hand ram to firm tits on both boxes. Watch #'s on prints when closing
(can go both ways)
Machine Shop
Start Date
Finish Date
Scrapped
Total Good
Eng Version
Comments
Signature
Layout/QC
Requirement
N/A
Signature
Final Layout
Machining
Verification
Casting
Delivery
Quantity Shipped
Signature
Date
Via
Machine Shop
Machining
Machine Shop
Machining
Machine Shop
Machining
Machine Shop
Machining