![Page 1: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/1.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
What’s Driving the Cost of
Your Casting?
Dave Charbauski
Caterpillar Inc. (Retired)
![Page 2: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/2.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Personal Profile
Current: Casting Quality and Sourcing Consultant
Experience: 22 Years at Caterpillar • Purchasing & Supplier Quality
17 Years in Foundry Management• Iron, Steel & Nonferrous Castings
![Page 3: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/3.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Target Cost:X
Has This Ever Happened To You?
![Page 4: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/4.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Target Cost:X
Supplier A + 45%
Supplier B + 55%
Supplier C + 40%
Quotes Received
Has This Ever Happened To You?
![Page 5: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/5.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Target Cost:X
Supplier A + 45%
Supplier B + 55%
Supplier C + 40%
Quotes Received
?
Has This Ever Happened To You?
![Page 6: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/6.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
What do you do next?
Options
1. Find a new supply base
![Page 7: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/7.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
What do you do next?
Options
1. Find a new supply base
2. Go into the Foundry business yourself
![Page 8: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/8.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
What do you do next?
Options
1. Find a new supply base
2. Go into the Foundry business yourself
3. Investigate your design for cost drivers
![Page 9: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/9.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
What do you do next?
Options
1. Find a new supply base
2. Go into the Foundry business yourself
3. Investigate your design for cost drivers
Why should I look at the design?
![Page 10: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/10.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Design 5%
Material 50%
Labor 15%
Overhead 30%
Initial Effect
Design Impact on Product Cost Over Time
![Page 11: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/11.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Design 5%
Material 50%
Labor 15%
Overhead 30%
Initial Effect Long Term Effect
Design 70%
Material 20%
Labor 5%Overhead 5%
Design Impact on Product Cost Over Time
![Page 12: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/12.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Design 5%
Material 50%
Labor 15%
Overhead 30%
Initial Effect Long Term Effect
Design 70%
Material 20%
Labor 5%Overhead 5%
Design Impact on Product Cost Over Time
Potential Casting Impacts
• Higher Scrap Rates
• Increased Rework
• Delivery Problems
• Increased Costs
![Page 13: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/13.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
![Page 14: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/14.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
![Page 15: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/15.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
• Would changing to a standard grade meet your requirements?
![Page 16: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/16.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
• Would changing to a standard grade meet your requirements?• Could a lower cost material be utilized?
![Page 17: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/17.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Metal Type• Standard grade or unique chemistry?
• Would changing to a standard grade meet your requirements?• Could a lower cost material be utilized?
• Commonly poured or periodically scheduled?
![Page 18: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/18.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?
![Page 19: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/19.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?• Being on either end of the spectrum can be costly
![Page 20: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/20.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?• Being on either end of the spectrum can be costly
• Smaller/lighter castings may experience higher levels of scrap due to shakeout damage.
![Page 21: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/21.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Casting Weight and Size• How well does your casting fit within the foundry’s weight
and size parameters?• Being on either end of the spectrum can be costly
• Smaller/lighter castings may experience higher levels of scrap due to shakeout damage.
• Larger/heavier castings may require extended cooling time causing a slow down on an automated line.
![Page 22: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/22.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
![Page 23: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/23.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
• Small lot sizes can be difficult in a high production foundry.
![Page 24: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/24.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
• Small lot sizes can be difficult in a high production foundry.
• How many orders per year?
![Page 25: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/25.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Reality Check
Does the part fit the foundry?
Annual Volume• How many pieces do you plan on buying per year?
• Small lot sizes can be difficult in a high production foundry.
• How many orders per year?
• Consult with your foundry to determine if your volume is considered low, medium, or high.
![Page 26: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/26.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
OK - Everything fits! What’s next?
![Page 27: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/27.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
OK - Everything fits! What’s next?
Time to dig deeper into the casting design to identify
cost drivers
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www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Draft angles and finish stock allowance• Draft
• Excess draft can add weight• Insufficient draft can increase scrap and rework
• Most foundries need 1 to 2 degrees
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www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Draft angles and finish stock allowance• Draft
• Excess draft can add weight• Insufficient draft can increase scrap and rework
• Most foundries need 1 to 2 degrees
• Finish Stock• Amount can vary with material type, casting size, and molding
process• Excess stock adds weight and increases machining costs• Insufficient stock can shorten insert life and increase scrap due to
tool breakage and non clean-up
![Page 30: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/30.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Parting lines• Flat, straight partings lines are a best practice
![Page 31: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/31.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Parting lines• Flat, straight partings lines are a best practice• Offset parting lines are common, but…
• Can increase pattern cost• Are more likely to produce parting fins• Can cause mold compaction issues
![Page 32: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/32.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Parting lines• Flat, straight partings lines are a best practice• Offset parting lines are common, but…
• Can increase pattern cost• Are more likely to produce parting fins• Can cause mold compaction issues
• Can you minimize the effect of the parting line?
![Page 33: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/33.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Parting lines• Flat, straight partings lines are a best practice• Offset parting lines are common, but…
• Can increase pattern cost• Are more likely to produce parting fins• Can cause mold compaction issues
• Can you minimize the effect of the parting line?
![Page 34: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/34.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Cores• Look for ways to minimize or eliminate cores
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www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Cores• Look for ways to minimize or eliminate cores• Can you incorporate several cores into one?
• Be aware of the assembly cost• Make sure the assembly is robust
![Page 36: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/36.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Cores• Look for ways to minimize or eliminate cores• Can you incorporate several cores into one?
• Be aware of the assembly cost• Make sure the assembly is robust
![Page 37: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/37.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Cores• Long cores may require chaplets for support
• Cost for chaplet, placement, and finishing• Potential for increased scrap rate
![Page 38: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/38.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Section Thickness• Thin sections
• Can be susceptible to misrun and cracking
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www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Section Thickness• Thin sections
• Can be susceptible to misrun and cracking
• Thick sections• May be prone to shrinkage problems
• Isolated heavy sections should be avoided
![Page 40: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/40.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Section Thickness• Thin sections
• Can be susceptible to misrun and cracking
• Thick sections• May be prone to shrinkage problems
• Isolated heavy sections should be avoided
![Page 41: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/41.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Section Thickness• Variations in wall thickness can lead to higher scrap rates
![Page 42: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/42.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Section Thickness• Variations in wall thickness can lead to higher scrap rates• Transition design
• Abrupt transitions are stress raisers
![Page 43: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/43.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Section Thickness• Variations in wall thickness can lead to higher scrap rates• Transition design
• Abrupt transitions are stress raisers
Which transition is best?
![Page 44: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/44.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
![Page 45: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/45.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
• Grinding• Does the parting line need to be ground flush?
• Can the foundry design the pattern to eliminate the need for parting line grinding?
• Can raised pads be used for riser and ingate connections?
![Page 46: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/46.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
• Grinding• Does the parting line need to be ground flush?
• Can the foundry design the pattern to eliminate the need for parting line grinding?
• Can raised pads be used for riser and ingate connections?
• Cleaning• Is re-blast after grinding necessary?• Cleanliness of internal passages
![Page 47: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/47.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Finishing Requirements• How clear are your finishing instructions?
• Over processing leads to waste
• Grinding• Does the parting line need to be ground flush?
• Can the foundry design the pattern to eliminate the need for parting line grinding?
• Can raised pads be used for riser and ingate connections?
• Cleaning• Is re-blast after grinding necessary?• Cleanliness of internal passages
• Packaging • All specific needs should be known before the quoting stage
• Paint, container type, rust protection, packaging methods
![Page 48: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/48.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
![Page 49: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/49.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?
![Page 50: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/50.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
![Page 51: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/51.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
![Page 52: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/52.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
• Use surface finish comparators • C9 Microfinish Comparator
![Page 53: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/53.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
• Use surface finish comparators • C9 Microfinish Comparator• SCRATA plates
![Page 54: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/54.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Surface Finish Requirements• Must be defined early in the design process
• Think about the application• Is the casting visible or a touch point?• Visually defect free can add 15%+ to the cost
• Process can be engineered to minimize problems
• Use surface finish comparators • C9 Microfinish Comparator• SCRATA plates• MSS SP-55
![Page 55: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/55.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Tolerances• Cast tolerances are influenced by many factors -
![Page 56: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/56.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Tolerances• Cast tolerances are influenced by many factors -
• Metal type
![Page 57: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/57.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process
![Page 58: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/58.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
![Page 59: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/59.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
• Follow industry standards whenever possible
![Page 60: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/60.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
• Follow industry standards whenever possible
• Pattern considerations• Materials
![Page 61: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/61.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Tolerances• Cast tolerances are influenced by many factors -
• Metal type• Type of molding process• Size and weight of the casting
• Follow industry standards whenever possible
• Pattern considerations• Materials• Construction method• Pattern cost vs Dimensional stability
![Page 62: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/62.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Inspection Requirements• Understand the basic inspections that will be performed
![Page 63: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/63.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit
![Page 64: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/64.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit• Magnetic particle
![Page 65: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/65.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit• Magnetic particle
• Additional inspection
![Page 66: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/66.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Inspection Requirements• Understand the basic inspections that will be performed
• Typically a Brinell audit• Magnetic particle
• Additional inspection• Material certifications• Hardness testing• Ultrasonic inspection• Radiography• Pressure testing
![Page 67: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/67.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Keys to Success
![Page 68: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/68.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
![Page 69: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/69.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
Early Foundry Involvement• Start at the concept phase if possible
![Page 70: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/70.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
Early Foundry Involvement• Start at the concept phase if possible
Collaboration• Make sure your needs and expectations are known
![Page 71: Dave Charbauski Caterpillar Inc. (Retired) · • Finish Stock • Amount can vary with material type, casting size, and molding process • Excess stock adds weight and increases](https://reader035.vdocuments.site/reader035/viewer/2022081607/5ee2dc5cad6a402d666d1604/html5/thumbnails/71.jpg)
www.afsinc.org │ CastingConnection.afsinc.org │ @AmerFoundrySoc
Keys to Success
Goal is to eliminate or minimize cost drivers before the design is finalized
Early Foundry Involvement• Start at the concept phase if possible
Collaboration• Make sure your needs and expectations are known
Design Reviews• Everyone touching the part should be involved