Metal Casting Technologies : MCT DEC 2017 (4TH QRT)
METAL Casting Technologies 4th Quarter 2017 27 26 www.metals.rala.com.au TECHNICAL FEATURE EUROGUSS 2018 When: 9-11 January 2018 Where: Exhibition Centre Nuremberg, Nuremberg – Germany Web: www.aluminium-messe.com 66TH INDIAN FOUNDRY CONGRESS AND CAST INDIA EXPO EXHIBITIONS When: 10-12 January 2018 Where: Helipad Grounds, Gandhinagar, Gujarat – India Web: www.ifcindia.net/ GUANGZHOU INTERNATIONAL FOUNDRY DIECASTING & FORGE INDUSTRY EXHIBITION When: 4-6 March 2018 Where: China Import and Export Fair, Guangzhou – China Web: 10times.com/foundry-and-diecasting INDO FORGING 2018 When: 7-9 March 2018 Where: Indonesia Convention Exhibition – Pagedangan – Indonesia Web: www.indonesiametalworkingweek .com/ indo-forging/ DIEMOULD INDIA When: 11-14 April 2018 Where: BCEC, Mumbai – India Web: www.diemouldindia.org/ INTERMOLD When: 18-21 April 2018 Where: INTEX Osaka, Osaka Prefecture – Japan Web: intermold.jp/ METAL & STEEL SAUDI ARABIA When: 29 April – 2 May 2018 Where RICEC, Riyadh – Saudi Arabia Web: www.metalsteelsaudi.com/ METAL PLUS METALLURGY CHINA When: 16-19 May 2018 Where: China International Exhibition Center, Beijing – China Web: www.10times.com/metal-metallurgy-china INT’L METAL & METALLURGY EXHIBITION When: 6-8 June 2019 Where: China Import And Export Fair, Guangzhou – China Web: www.julang.com.cn/english/index.asp DIE & MOULD CHINA When: 5-9 June 2018 Where: National Exhibition and Convention Center, Shanghai – China Web: www.diemouldchina.com/en/ HEAT TREATMENT AND INDUSTRIAL FURNACE EXHIBITION When: 6-8 June 2018 Where: China Import And Export Fair, Guangzhou – China Web: www.julang.com.cn/english/reculi/ GUANGZHOU INT’L EXHIBITION OF CASTING PRODUCTS When: 6-8 June 2018 Where: China Import And Export Fair, Guangzhou – China Web: www.castingchina-gz.com/ NON-FERROUS METALS EXHIBITION When: 6-8 June 2018 Where: China Import And Export Fair, Guangzhou – China Web: www.julang.com.cn/english/yousejinshu/ DIE-CASTING, FOUNDRY AND INDUSTRIAL FURNACE EXHIBITION When: 6-8 June 2018 Where: China Import And Export Fair, Guangzhou – China Web: www.julang.com.cn/english/yazhu/ STAINLESS STEEL INDUSTRY EXHIBITION When: 6-8 June 2018 Where: China Import And Export Fair, Guangzhou – China Web: www.julang.com.cn/english/buxiugang/ INTERMOLD THAILAND When: 20-23 June 2018 Where: BITEC – Thailand Web: www.intermoldthailand.com/ ALUMINIUM CHINA When: 18-20 July 2018 Where: SNIEC – Shanghai New International Expo Centre, Shanghai – China Web: www.aluminiumchina.com/ FURNACES NORTH AMERICA When: 8-10 October 2018 Where: Indianapolis Convention Center – Indiana – USA Web: www.furnacesnorthamerica.com/ AFI NATIONAL CONFERENCE 2018 When: 12-14 October 2018 Where: SeaWorld Nara Resort, Gold Coast – Australia Web: www.australianfoundryinstitute.com.au EVENTS Savings from reclamation Reclamation of sand, when practiced, results in the following savings: l Cost of new sand is saved by reclamation. The cost of new sand includes the purchased price of new sand, freight cost and cost of unloading. The freight is variable depending upon the distance of a foundry from the source of the sand of required quality. l Cost of disposal of used is also saved by disposal. The cost of disposal includes cost of transport and labour. The transport cost may vary depending upon the distance of the foundry to the dumping site. Even a charge for dumping may have to be paid for dumping the waste sand. l Angular or sub-angular sand grains tend to be rounded by reclamation. This fact reduces the requirement of binder for the same strength properties. l Reclamation makes the surface of sand grains smoother compared to the original sand. It reduces the requirement of binder. l When reclamation system introduced, it reduces the space required for storage of new sand. Conclusion Dry reclamation of green sand and thermal reclamation of resin bonded sand are quite effective for their reuse in moulding and core making. However the cost of reclamation is to be compared with the cost of new sand. Costing will vary from one foundry to another depending upon the quality of sand required for the casting to be produced and the distance of the source of that sand from the foundry. Reclamation of good quality sand may be considered in spite of its higher cost keeping in view of its scarcity and conservation. n REFERENCES 1) P. R . Brawler and M. F. Burditt, Modern Casting, Vol.78, No.5, (1988) P.27 2) J. Danko, J. L . Lewandowski, Przeglad Odlewnictwa, Vol. 49, (1999) pp.91-93 3) D. S Leidel, Foundry Trade Journal, Vol.168, (1994) pp.384-387. 4) J. Danko, R. Danko and M. Holtzer, Metalurgija, Vol.42 (2003), pp.173-177. 5) Report of Simpson Technologies, Sand Reclamation,Application#500 6) John M. Svoboda, The ERI, CMP Report No. 90-6. SO RE WA FT he first step toward a smart metal casting process is the adoption of a modern, next-gen Computerised Maintenance Management System (CMMS) to collect, store and analyse data which should be accessible anytime, anywhere and by any team member. The best systems should be able to seamlessly connect to all other company systems as Enterprise Resource Planning (ERP), and all types of sensors in order to provide valuable data to determine which predictive maintenance strategies can be created and applied. There is no doubt that maintenance managers would rather spend their time defining and classifying important data analysis rather than trying to integrate endless excel, or even paper spreadsheets, into an old-fashioned system which usually causes delays and inaccuracies in the whole production planning cycle. A smart CMMS optimises the entire casting process by shifting maintenance from reactive to predictive. Companies can obtain a competitive advantage by investigating valuable insights drawn from spare parts inventory, equipment behaviour, team member performance, established processes within other company departments and many other sources. There is never a right moment to start the digital transformation. At first glance, all available solutions and the endless information flow can be quite overwhelming, but once in place, data collection, remote monitoring and a smart CMMS can be worth the investment. What are the benefits of the new technologies within the foundry industry? The following case study will provide an insight. Fonderie et Mécanique Générale Castelbriantaise (FMGC) is a European leader in the manufacture of cast iron counterweights. The company is the casting division of Farinia Group. Innovating continuously, FMGC has recently been diversifying its range of products to serve the marine renewable energy sector. For maintenance, FMGC wanted to use top-notch technologies. Some time ago the maintenance team purchased a conventional CMMS which was expensive, hard to implement, required a lot of long training sessions and was far from being user-friendly. Three years ago FMGC started using Mobility Work, the next-gen Maintenance Management Platform. The performance has significantly improved the production cycle by connecting to all departments including the management of spare parts which is now very well organised. The following points, directly linked to the adoption of the next-gen CMMS, created added value to the company’s maintenance process: l Managing maintenance interventions and purchasing requests and their follow-up l Managing inventory, purchasing and renewal of equipment l Creating a history of all performed maintenance tasks, following equipment and stock movements l Creating alerts l Managing meter readings, including in the field via a mobile terminal l Easily changing maintenance tasks and operating procedures l Performing self-help troubleshooting l Scheduling maintenance operations l Managing risks and regulatory constraints Future outlook The concept of a smart factory and therefore smart maintenance spanning across smart devices, represents a huge opportunity for next-gen CMMS and the Industrial Internet of Things (IIoTs) to improve equipment reliability and minimise maintenance costs. CMMS analytics turns the IIoTs big data into a powerful instrument facilitating innovative business models that leverage advanced traceability, connectivity and intelligence. For the casting industry in particular, this means increased flexibility toward late product changes and supply chain disturbances. Smart foundries are still quite rare but it is important to understand now what can be implemented to prepare for the future. There are already many solutions available at the market and starting with a sophisticated CMMS and a couple of sensors are definitely not a bad idea. Business owners who dare to follow digital integration will gain a competitive advantage and be far more reactive to customer needs. n Smart maintenance process for a casting plant By Ralitsa Peycheva T FMGC maintenance team utilizing the mobility work app in the field.
MCT MAR 2018 (1ST QRT)