dura-bar continuous cast ironthe chart on the right provides the material properties of dura-bar...
TRANSCRIPT
Dura-Bar Continuous Cast Iron Machine More Parts per Hour • Decrease Costs and Improve Profitability • Increase Productivity
Break o�
Hold down
Crucible
Notching saw
Grippers
Control panel
Roll strands andstrand supports
Gray Iron Ni-Resist•Excellentwearresistance•Vibrationdamping•Superiorsurfacefinish•Respondswelltoconventional heattreatmethods HeatTreatMethods
• Idealforcorrosive environments
1. Agraphitedieismachinedtoform theshapeofthebar(Round,Square, Rectangle,oraCustomShape)
2. Thedieismountedtothebottomofa crucibleinawater-cooledjacket
3. Thebarispulledhorizontally throughthedie
Dura-Bar Continuous Casting Process
4. Anyimpuritiesfloattothetopofthe crucible,allowingonlythehighestquality irontoenterthedie.Theresulting materialis:
• Freeofdefectstypicallyassociatedwith castiron
• Densewithafine-grainedmicrostructure
• Highlymachinable
•Alternativetolow&medium carbonsteel•Excellentmachiningproperties•Lowerheattreatcostsvssteel•Comparablestrength
Ductile Iron
Various Grades:
Rounds Squares/RectanglesAs-CastorCold-Finished
Tubes CustomShapesAs-Cast
Cut-To-SizeCut-to-Length
Dura-Bar Shapes and Sizes
Molteniron
Water �ow
Cast barGraphite die
Water cooler
Refractorylining
Crucible
Arecentindustry-widestudyconductedbyamajortoolingmanufacturerdeterminedthattheaveragecosttomanufactureacomponentbreaksdownasfollows:5%toolingcost,20%materialcostand75%manufacturingcost.
Thegraphicbelowillustratesthecostreductionpossibilitiesofsaving30%ineachcostcategory.ThetruebenefitofDura-Barcomesfromthereductioninmanufacturingtimewhichgenerallymakesupthelargestpercentageofacomponent’scost.
Forexample,a30%reductioninmanufacturingtimeona$10component,wouldsave$2.25percomponent.Anannualvolumeof100,000pieceswouldincreaseyourprofitabilityby$225,000.
Reducing Manufacturing Costs
Cost Reduction:
Machining Dura-Bar
ManufacturingCosts.......$7.50
WorkpieceMaterial..........$2.00
CuttingTools.......................$.50
More Parts per Hour
Advantages of Dura-Bar:•Fastermachiningspeedsandfeeds
•Consistentlyoutperformsalternativematerials
•Lowersthetotalcostofmachinedcomponentparts
•Longertoollifeandlesstoolwear
Advantages of Graphite in Dura-Bar:•Enhancesmachiningbyactingasachipbreaker
•Reducesfrictionontheinsert&increasestoollife
• Improveswearperformanceintheapplication
•Graphiteisanaturallubricant
30%ReductioninToolingCost=$0.15
30%ReductioninMaterialCost=$0.60
30%ReductioninManufacturingTime=$2.25
More Parts Per Hour
TheuniquecontinuouscastingprocessusedtoproduceDura-Baryieldsanumberofcost-savingadvantagesformanufacturersofmetalcomponentswithoutsacrificingmaterialstrength.ThechartontherightprovidesthematerialpropertiesofDura-Bar65-45-12and80-55-06ductileironcomparedwithcommongradesofsteel.
Comparable StrengthDura-Bar vs Steel
Material PropertyDura-Bar Hot Rolled Steel
65-45-12 80-55-06 1018 1045 1117 1144 12L14
TensileStrength(psi/ksi) 65,000 80,000 58,000 81,900 58,000 102,000 57,300
YieldStrength 45,000 55,000 31,900 45,000 31,900 60,900 34,100
Elongation(%In2") 12 6 25 16 25 21 22
Hardness–Average(BHN) 180 229 116 163 116 212 121
Insituationswhereproducingacomponentrequiresahighdegreeofturning,milling,drilling,and/ortapping,usingDura-Barwillresultindramaticsavingsinmachiningcosts.
Faster Machining
1212 Steel = 100%
G2
65-45-12
80-55-06
100-70-03
8620
1045
1117
12L14
0%20%40%60%80%100%120%140%160%
Machinability RatingG
rade
Dura-Bar vs Steel
Machine at Higher Speeds with Reduced Tool Wear
Dura-Bar vs Steel (continued)
TheDura-Baradvantageistheabilitytomachineathigherspeedswithoutnegativelyimpactingtoollife.
• Toollifeisoftenupto2timeslonger at800SFM
• Comparablemechanicalproperties,beforeand afterheattreat
• Dura-Baris8%lighterbydensityandhas superiorvibrationdampingproperties
• Superiorwearresistance
Advantages of Dura-Bar vs Steel
Dura-Barductileironchips;consistentandcontrollablechipformation
Steelchips;typicalstringyanduncontrollablechipformation
1045 1117 80-55-06 G2 65-45-12
0 400200 600 800 1000 1200 1400SFM
Inse
rt W
ear R
ate
Wear Rate Comparison
Machinability ratingsbased on tool life
di erences at 450 sfm
Dura-Bar Ductile ironis often machined at
speeds exceeding1000 sfm
Dura-Bar vs Steel (cont.)
Dura-Bar vs Castings
•Continuouscastingprocesseliminates typicalcastingdefects
•Densefine-grainedmicrostructure
•Zero-DefectGuarantee
•Superiorsurfacefinish
Advantages of Dura-Bar vs CastingsDura-Bar vs Castings
Dura-Barcontinuouscastironisahighqualityalternativetocastings.WithDura-Bartherearenodefectslikethosetypicallyfoundincastings–e.g.,porosity,slag,hardspots,shrinkage,etc.Infact,Dura-BarcomeswithauniqueZeroDefectGuaranteethatnotonlyprovidesforthereplacementofanydefectivematerial,butalsoforreimbursementofcostsinvolvedwithmachiningit.*
Dura-Bar SandCasting
•Nopatternortoolingcosts
•Fastermachiningandreducedtoolwear
•Over500sizesavailablefrominventory
•Minimalcarbides
Dura-Bar’s Zero Defect Guarantee
For a complete description of the Zero Defect Guarantee, including a description of the exclusions and limitations that apply to such guarantee, please see: www.dura-barms.com/dura-bar/zero-defect-guarantee.cfm
*
Inhigh-pressurehydraulicapplications,Dura-Barconsistentlyoutperformsaluminum.Aluminumisgenerallynotusedinpressureapplicationsgreaterthan3,000psi.
Tough Under Pressure
Dura-Bar vs Aluminum
•Higherfatiguestrengths
•Higherelasticmodulus(underthesameload aluminumwilldeflectanddistortmorethan twiceasmuchas65-45-12)
•Littleornodeburringrequired
Incontrast,Dura-Barductileironhasbeenpressureratedto6,500psi.*Therefore,amanifoldproducedfromDura-Barcanoperateatmuchhigherpressuresthananaluminummanifoldwiththesamedesign.Assystemsgetsmaller,withthinnerwallsections,Dura-Bar’shigherpressureratingversusaluminummakesforaneasymaterialselectioninpressurecontainingapplications.
Advantages of Dura-Bar vs Aluminum
Material Property 6061-T6 2024-T3 65-45-12
Hardness(BHN) 95 120 180
TensileStrength(psi) 45,000 70,000 65,000
YieldStrength(psi) 40,000 50,000 45,000
Elongation(%) 12 19 12
ElasticModulus(psi) 10,000,000 10,600,00 25,000,000
FatigueStrength(psi) 14,000 20,000 40,000
Density(lbs/in3) 0.098 0.100 0.255
ThermalExpansion(micro-in/in/F) 13.1 12.9 5.5
Dura-Bar consistently outperforms aluminum
* Rated in accordance with NFPA T2.6.1
Dura-Bar vs Aluminum
The possibilities are endless…
CylinderLinerCylinderLiner CylinderLiner HydraulicManifold HydraulicManifold RotaryVanePumpMotor
HydraulicCylinderPiston
HydraulicHousingPumpHousings
Bushing LawnTractorBushing
WaterPumpBushing
Camshaft HydrostaticCylinderSwashPlate
GlassMoldPlunger
SealingBlock
PistonPumpCylinderBlock
HydraulicSwivelClamp
HydraulicSwivelClamp
FlexibleShaftCoupling
HydraulicHoseCoupling
ShaftCoupling
GyrotorRing SealingRingsMachineToolChuck
BearingCap
HydraulicHoseFitting
RadialPumpCylinder
AccessoryDriveGear
TransmissionPlanetaryGear
BalanceShaftGear
SteelMillRoll ChainLinkRoller
RadialPumpCylinder
LockCylinder
CrankShaftGear
CamGear OilPumpGear
EnginePumpGear
DistributorGear
VanePumpRotor
CompressorRotorCamGearBalanceShaftGears
DieselPumpGear
HydraulicOilPumpGear
SynchronizingGears
TimingGear WastePumpGear
HydraulicSwivelSpool
HydraulicSwivelHydraulicOilPumpGear
HydraulicOilPumpGear
CoffeeGrindingRoller
HydraulicCylinderRodGuide
FeederScrew HydraulicSwivel BeltPully LockSleeve SpoolPoppetHydraulicCylinderPiston
Bushing
Dura-Bar Applications
Woodstock,Illinois2195W.LakeShoreDriveWoodstock,IL60098Phone:888-DURA-BARFax:815-338-4608
Salisbury,NorthCarolina770CedarSpringsRd.Salisbury,NC28147Phone:888-DURA-BARFax:704-637-9736
York,Pennsylvania90GrumbacherRd.York,PA17404Phone:888-DURA-BARFax:973-589-3645
dura-barms.com