Effort Foundry IncTechnology is the buzzword heard around the foundry today
NEW TECHNOLOGY OVERVIEWEFFORT FOUNDRY IS MAKING HUGE INVESTMENTS INTO NEW
TECHNOLOGY AS A PART OF OUR CONTINUOUS IMPROVEMENT PROGRAM TO BETTER SERVE OUR CUSTOMERS
• PRECISION MACHINING
• SOLID MODELING
• SOLIDIFICATION SIMULATION
• MACHINING SIMULATION
• 3D LASER SCANNING
• LASER MARKING
• ADDITIVE MANUFACTURING3D printing is currently outsourced with plans in place for it to be added to in-house capability
IN-HOUSE MACHININGTECHNOLOGY OVERVIEW
• VERTICAL TURNING
• HORIZONTAL TURNING
• HORIZONTAL MILLING
• VERTICAL MILLING
• KEYWAY CUTTER
• COMPETENCIES
• ROUGH MACHINING CASTINGS
• FINISH MACHINING CASTINGS
• PATTERNS AND PATTERN COMPONENTS
• BENEFITS
• VALIDATE CASTING QUALITY
• LOCATE AND UPGRADE SHRINK, INCLUSIONS, CRACKS, ECT…
• VALUE ADDED SERVICE TO CUSTOMER
• ONE STOP SUPPLIER
• DELIVERY
• FASTER REACTION TIME
• MACHINING ON CUSTOMERS SCHEDULE
VERTICAL TURNING WITH MILLING
• ROUGH & FINISH MACHINING• PART DIAMETERS UP TO 40”• PART LENGTHS TO 35”• MILLING ON TOP AND SIDE• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER
VERTICAL TURNING WITH MILLING
• TURNING• MILLING• DRILLING• TAPPING• TOP FEATURES• SIDE FEATURES
HORIZONTAL MILLING• ROUGH & FINISH MACHINING• (2) ROTARY DEVICES FULL 5 AXIS • X TRAVEL 40”• Y TRAVEL 30”• Z TRAVEL 25”• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER
HORIZONTAL MILLING• MILLING• DRILLING• TAPPING • MACHINING ON 5 SIDES IN ONE HOLDING
VERTICAL MILLING• ROUGH & FINISH MACHINING• X TRAVEL 30”• Y TRAVEL 20”• Z TRAVEL 20”• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER
VERTICAL MILLING• MILLING• DRILLING• TAPPING
HORIZONTAL TURNING• ROUGH & FINISH MACHINING• PART DIAMETERS UP TO 40”• PART LENGTHS TO 60”• MILLING ON FRONT AND SIDE• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER
HORIZONTAL TURNING• TURNING• MILLING• DRILLING• TAPPING• FRONT FEATURES• SIDE FEATURES
KEYSEATER• KEYWAYS FROM 1/16” TO 1-1/2” WIDE
• UP TO 12” LONG
Solid Modeling and SimulationTechnology Flowchart
3D Model Parts
from 2D
Solidification Simulation
3D PrintedPlastic
CAM
SolidWorks
Create Machine Tool
G-Code
3D Model Patterns from 2D
Verify Casting Process
Verify Heat Treat
Process
Complex Pattern
Components
Complete Patterns
Rough and Finish
Machining of Castings
Machining of New Patterns
Verify Material
Stress
3D ScanningTechnology Flowchart
3D Scanner
Solidification Simulation
Assemble 3D Mold
Scan Casting
Scan Pattern
Solidworks
Solidworks 3D Model Casting
InspectPattern
CAMESPRIT
Inspect Casting
Dimensional Reporting
Dimensional Reporting
Laser MarkingTechnology Flowchart
Rough Machined
Effort Foundry
EFI Vendor
Customer
Laser Marker
Permanent Part
Identification
Finish Machined
In-house Part
Verification
Part ID for Outside
Processing
Completely Customizable Per
Customer Requirements
Part #Heat #
Pattern #Material
Part #Heat #
Pattern #Material
Additive Manufacturing (3D Printing)Technology Flowchart
3D printing is currently outsourced with plans in place for it to be added to in-house capability
PatternsComplex
Geometry
3D Printing
3D Printed Pattern
Components
Molds& Cores
Complex Geometry
3D Printed Complete Patterns
3D Printed Molds &
Cores
Plastic
Sand
Complete Parts
Complex Geometry
3D Printed Parts
MetalCurrently In Research &
Development Dept
Measure Pattern3D Scan
Model in Solidworks
Import to ProCast Simulate
Fail
Pass
Ready to Mold
Modify Model in
Solidworks
3D Scanning
3D Scanning
For Inspection
3D Printing In
EffortFoundry
Model Casting in Solidworks
Model Rigging in Solidworks
Import to ProCast Simulate
Fail
Pass
Ready to Mold
Modify Model in
Solidworks
Model Finished
Machined Part in
Solidworks
Model Adding .06 to
Finished Surfaces
Model the As-Cast
for Material Removal
Ready for Machine
Shop
In-house Drawings
made and
checked
Create Toolpathfor Rough and Finish
Model Finished
Machined Part in
Solidworks
Model Adding .06 to
Finished Surfaces
Model the As-Cast
for Material Removal
In-house Drawings
made and
checked
Create Toolpathfor Rough and Finish
Rough Machine
to Drawing
NDT and Upgrade
Ready to Ship
Finish Machining Required?
No
YesFinish
Machine to Drawing
Final Dimensional Verification
Validate Casting
“Baseline”
Validate Casting
“Baseline”
Rough Machine
to Drawing
Finish Machine
to Drawing
Patterns Too!