1) Master Pattern Design: Precise Cast converts 3-D CAD data into a master pattern. Gating (rigging) and shrink compensation are factored into the CAD during this tooling design phase. Depending on part geometry, FEA solidification analysis is run to optimize the tooling design.
2) Match Plates/Tooling: A 3-D solid model is used to machine a match plate.
3) Forming the Mold: Sand is mixed with the proper chemicals for binding. A compaction table is used to ensure optimal compaction. The sand mixture is metered into the match plates where it is left to harden. The mold halves (cope and drag) are then removed from the match plates, and assembled for metal pouring.
4) Pouring the Metal: A gravity pour method of filling the cavity is used. Variables that affect casting quality are carefully controlled. These variables include metal temperature, mold temperature, cooling rate, mold tilt, riser size and location, and metal filtering. We use rotary degassing, a continuous melt furnace, and employ a reduced atmospheric testing system to ensure optimal results. Each mold and corresponding part is serialized.
5) Break Out: After the metal has solidified, the sand is carefully broken away to reveal the metal casting.
6) Parts Cleaning: Next comes the removal of gates, chills, runners, and minor casting imperfections. The result is a “raw” casting.
7) Machining: Final machining is often used to create high-tolerance geometries that are either beyond the capabilities or not economical to incorporate into the casting process. We have a machining department dedicated to the machining of castings. Our technology includes multi-axis capability and probe technology to ensure consistent and accurate machining of each casting.