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MELTING
Core Sand & Additives Purchased Metal
SAND PREPARATION
Binders, New Sand, Additives Sand Preparation
Metal Charging Melting Alloying Recycle Waste Metal (Sprues, Gates, Risers, Runners,
CORE MAKING
Core Making
Scrap
Mold Making -Pack Sand - Set Cores -Add risers, gates, filters
CASTING PROCESS
Pour Solidification & Cooling Shakeout Cleaning Finishing In-line Inspect
SECONDARY
Heat Treat Off-line Inspection Secondary Processes (Machining, ) Heat Treat
Chaplets
aPriori VPEs
Process Capability & Routing Rules
Customer VPEs
Physical Manufacturing Capabilities
Supplier VPEs
Cost Models
P
Melting
Core Making
Shakeout
Cleaning
Finishing
In-line Inspection
Oil Core
Vertical Automatic
C02 Cured Hot Box Isocure Gas No bake Shell Stock/Extruded None or all of these can be part of the process Mold Making Pouring Cooling
Horizontal Automatic
Mold Making Pouring Cooling
Manual Standard
Mold Making Pouring Cooling
Manual Floor
Mold Making Pouring Cooling
32 x 6 x 6
X X X X X X
Molding Type Selection -Compares part size to machine flask size for each machine in the mold type -Selects first feasible machine -Calculates the number of cavities that will fit in the mold
Molding Selects first feasible based on part and machine size Core Making Selects first feasible process that can fabricate all cores based on core box size
Pour Selects first feasible based on part weight and ladle capacity
Time Calculations -Calculated for each feasible routing -Machine Cycle Time -Machine Setup Time -Labor Handling Time Material Calculations -Yields -Material Utilization
2009-2010 aPriori Confidential, all rights reserved
Check Minimum Thickness Compares minimum wall thickness of part to minimum allowable wall thickness from material table
Recommendation: leave draft, rounds, min thickness unchecked until design matures
2009-2010 aPriori Confidential, all rights reserved
Variable Costs Material Labor and Overhead Setup Capital Investments Pattern Making Core Box Amortized Investments Investment per Part Expendable Tooling Sand for cores and molds
2009-2010 aPriori Confidential, all rights reserved
Limitation: If a model contains a machined part, its cast version AND other subcomponents, aPriori will still interpret it as an assembly.