Entries13 inches x 24 inches printed www.allendesigners.com shelves
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June 9 A General Drafter
The title “general drafter” suggests that this type of draftsman or drafter draws most anything required of them to draw. And that is quite correct to a certain degree, as long as they are trained in various disciplines of drafting.
I will give you a for instance and you will need to read carefully to keep up. My original training involved mechanical drafting which is the art of making technical drawings for machine and fabrication shops. This was through courses given while I was in the U.S. Navy and in its self is one discipline.
When I left the navy, I found a job with a land surveyor who was willing to train me in the field of boundary and topographical survey drafting. This gave me my second drafting discipline. This surveyor from time to time would hire me out to an architect who worked closely with his surveying office. This particular architect would have me to revise his drawings according to his specifications. This exposed me to architectural drafting in a major way.
Then, later on in my career I trained in architectural drafting to create residential and commercial building plans from sketches and ideas of an architect. I apprenticed under this professional for years and from time to time was asked to create drawings for structural steel to be built in a steel fabrication shop for the buildings he designed by the steel fabricator that the architect worked closely with.
So far then I received training and experience in mechanical drafting, boundary and topographical drafting, then architectural, both residential and commercial, then steel fabrication. That adds up to four different disciplines so far.
Finally I opened a drafting office with a clientele that included a large area dairy company, two plastic injection molding companies, several home builders, an automotive parts manufacturer, a civil engineer, and two surveyors.
The injection molding companies had me create quite a few parts and then patent drawings over the years which added a fifth discipline of patent drafting. The dairy company hired me many times to create loading dock fixtures from their designs which added a sixth discipline in another form of mechanical drafting. The automotive company along with the dairy, and plastics manufacturers all had me to create plant layouts, which added a seventh discipline called industrial layout.
The plastics companies both had me to take the drawings I had created of their parts and turn them into sales brochures. Since many of these had to be in a real life type drawing, I had to learn and master 3D modeling. So that created the eighth discipline, commercial illustration.
And that is the definition of a general drafter. Actually, over the years I have had drafters under me, giving the title of senior and then master drafter. There is quite a bit that can be accomplished if you just put your mind to it. And mind you, this took well over thirty years to complete.
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The ordering of metal castings takes a certain amount of time and energy to qualify a potential supplier foundry. To get the best value from the metal casting also requires a cooperative effort on the part of the customer and the supplier foundry from the early stages of the design through to the end manufacturing process. Good planning ahead of time will pay dividends for both you (the customer) and your supplier foundry.
The purpose of requesting a quotation for a steel casting is basically to determine the lowest purchased casting cost. The customer then must weigh all of the provisions of the quotation including exceptions taken to drawings, specifications, and processing requirements, as well as supplier foundry experience, tooling requirements, tolerances, finish allowances, and delivery. Such factors as reduced machine work, better tolerances, improved delivery schedules and reliability are particularly important to determine the lowest end cost of the casting.
To avoid misunderstandings, reduce costs, and expedite the processing of quotations, all or some of the following information should be included in a request for a quotation:
Design – What is the part? See DESIGN below.
Quantity – What is the anticipated or required volume, both present and future?
Material and inspection requirements; what should the part be made of, and how should the part be tested before delivery? ASTM or other nationally recognized specifications should be used whenever possible to identify the material and inspection requirements. See MATERIAL SPECIFICATIONS and SOUNDNESS below.
Actual or estimated casting weight. Actual weight information is preferred. Estimates can be provided by the supplier foundry in the absence of actual weight information, but this may require offering prices that are subject to changes based on the actual weight of the casting(s) in question at the time of production.
Drawing. Machine drawings are preferred over casting drawings. Drawings or sketches are mandatory if samples or patterns are not available. Drawing should include dimensional tolerances, indications of critical areas and surfaces to be machined. See MACHINING below.
Pattern. If patterns and core boxes are available, the request for a quotation should indicate the type, condition and set up of the equipment. See PATTERNS below.
Production/delivery schedules required. Present and anticipated need should be included in quotation requests.
Beyond these basics, there are levels of customer requirements that could include supplier foundry liabilities, which affect the casting cost drastically. These could include receiving inspection acceptance and back charge policy, casting return policy, expediting procedures, and sophisticated controls not normally associated with the standard inquiry. A complete understanding of these areas is best developed by an open relationship between the customer and the supplier foundry representative, and the professional attitudes and experiences that both can provide during the quotation evaluation phase.
Design
To achieve the most efficient production and the highest quality product, the part should be designed to take advantage of the flexibility of the casting process. The supplier foundry must have either the designer’s drawings or pattern equipment and know the length of the run (number of parts to be made).
Castings are generally furnished with un-machined as-cast surfaces, unless otherwise specified. To take advantage of the casting process, the supplier foundry should also know which surfaces are to be machined and where datum points are located. The acceptable dimensional tolerances must be indicated when a drawing is provided. Tolerances are normally decided by agreement between the supplier foundry and customer. Close cooperation between the customer’s design engineers and the supplier foundry is essential to optimize the casting design.
Material Specifications
Industry standard specifications provide the casting customer with the tools necessary to establish criteria for almost any casting application. These specifications do not preclude special requirements that the customer’s technical staff members may require. Variations from standard specifications can result in misunderstandings, higher costs and disqualification of potential supplier foundries. If exception is taken to a provision in the main body of a specification requirement (as opposed to taking exception to a supplemental requirement of a specification), the resulting casting cannot be held to compliance with that specification.
Mechanical properties may be verified by the use of test bars cast either separately or attached to the castings. The mechanical properties obtained represent the quality of the steel, but do not necessarily represent the properties of the castings themselves, which are affected by solidification conditions and rate of cooling during heat treatment, which in turn are influenced by casting thickness, size and shape. In particular, the harden ability of some grades may restrict the maximum size at which the required mechanical properties are obtainable. Short of destructive testing of an actual casting sample, the use of a test bar is the best measure of the steel quality.
Soundness
Soundness of metal components refers to the level of freedom from impurities and/or discontinuities such as sand inclusions, slag inclusions, macro porosity, and shrinkage.
Steel castings begin to solidify at the mold wall, forming a continuously thickening envelope as heat is dissipated through the mold-metal interface. The volumetric contraction that occurs within a solidifying cast member must be compensated by liquid feed metal from an adjoining heavier section, or from a riser which serves as a feed metal reservoir and which is placed adjacent to, or on top of, the heavier section. The lack of sufficient feed metal to compensate for volumetric contraction at the time of solidification is the cause of shrinkage cavities. They are found in sections which, owing to design, must be fed through thinner sections. The thinner sections solidify too quickly to permit liquid feed metal to pass from the riser to the thicker sections.
Testing ensures that the material meets the requirements of the specification; consequently, testing may be mandatory. More frequent testing or other tests may be imposed, by use of supplementary requirements of material specifications or general requirement specifications. In addition to specifying test methods, acceptance criteria must be agreed upon between the purchaser and the foundry. The more testing and tighter the acceptance criteria the more expensive the product will be – without necessarily increasing quality or serviceability. Hence, the extent of testing and acceptance criteria should be based on the design and service requirements.
It is impossible to produce a defect free casting, only castings with defects of varying degrees of acceptability. The acceptance and/or rejection of such castings can only be determined by examination and analysis of parts (in accordance with internationally recognized standards such as ASTM) based on customers’ formal engineering requirements. A defect in one application may not be a defect in another application and it is impossible to make a casting without some kind of flaw. The size of flaw(s) can vary significantly, and what is acceptable and what is defined as a REJECTABLE defect depends on agreement between the supplier foundry and the client prior to production. Large cavities often exist in thick-section castings and can be perfectly acceptable depending on the application and the location within the casting. On the other hand, some applications are very critical and tiny flaws (or even micro-porosity – as defined by a specific NDT process and acceptance/rejection level) may be considered as defects that may be detrimental to the intended use of the product.
Acceptance and rejection criteria for castings production must be determined at the time of quotation and certainly at the time of order, as such criteria affect the price of castings, as well as the production procedures and processes used to produce the castings.
Patterns
Pattern equipment design and the resultant costs can constitute a major source of misunderstanding between customer and supplier foundry. The need to construct new pattern equipment when existing equipment is available, a requirement for a full split core box in place of a half core box, pattern material, and mounted or loose patterns are but a few of the many areas of discussion that effect the cost of the equipment. Invariably, the lowest casting cost and highest casting quality evolve from the more sophisticated pattern equipment, which generates the highest pattern cost.
Patterns – Minimum Section Thickness
The rigidity of a section often governs the minimum thickness to which a section can be designed. There are cases, however, when a very thin section will suffice, depending upon strength and rigidity calculations, and when castability becomes the governing factor. In these cases it is necessary that a limit of minimum section thickness per length be adopted in order that liquid metal will completely fill the mold cavity in these thinner sections.
Molten steel cools rapidly as it enters a mold. In a thin section, close to the gate, which delivers the hot metal, the mold will fill readily. At a distance from the gate, the metal may be too cold to fill the same thin section. A minimum thickness of 0.25 in (6 mm) is suggested for design use when conventional steel casting techniques are employed. Wall thicknesses of 0.060 in (1.5 mm) are common for investment castings and sections tapering down to 0.030 in (0.76 mm) can readily be achieved.
Patterns – Draft
Draft is the amount of taper (or the angle) which must be allowed on all vertical faces of a pattern to permit its removal from the sand mold without tearing the mold walls. Draft should be added to the design dimensions while maintaining minimum metal thickness.
Regardless of the type of pattern equipment used, draft must be considered in all casting designs. (Draft can be eliminated by the use of cores; however, this may add significant cost.) In cases where the amount of draft may affect the subsequent use of the casting, the drawing should specify whether this draft is to be added to or subtracted from the casting dimensions as given.
The necessary amount of draft depends upon the size of the casting, the method of production, and whether molding is by hand or machine. Machine molding will require a minimum amount of draft. Interior surfaces in green sand molds usually require more draft than exterior surfaces. The amount of draft recommended under normal conditions is about 3/16 in. per ft. (approximately 1.5 degrees), and this allowance would normally be added to design dimensions.
Patterns – Parting Line
Parting in one plane facilitates the production of the pattern as well as the production of the mold. Patterns with straight parting lines (that is, with parting lines in one plane) can be produced more easily and at lower cost than those with irregular parting lines. Casting shapes which are symmetrical about one center line or plane readily suggest the parting line. Such casting design simplifies molding and coring, and should be used wherever possible. They should always be made as “split patterns” (separate cope and drag) which require a minimum of handwork in the mold, improve casting finish, and reduce costs.
Patterns – Cores
A core is a separate piece (often made from molding sand) placed inside the mold to create openings and cavities which cannot be made by the pattern alone. Every attempt should be made by the design to eliminate or reduce the number of cores needed for a particular design to reduce the final cost of the casting.
The minimum diameter of a core which can be successfully used in steel castings is dependent upon three factors:
1. The thickness of the metal section surrounding the core
2. The length of the core
3. The special precautions and procedures used by the supplier foundry.
The adverse thermal conditions to which the core is subjected increase in severity as the metal thickness surrounding the core increases, and the core diameter decreases. These increasing amounts of heat from the heavy section must be dissipated through the core. As the severity of the thermal conditions increases, the cleaning of the castings and core removal becomes much more difficult and expensive.
The thickness of the metal section surrounding the core, and the length of the core, both affect the bending stresses induced in the core by buoyancy forces and, therefore, the ability of the supplier foundry to obtain the tolerances required. If the size of the core is large enough, rods can often be used to strengthen the core. Naturally, as the metal thickness and the core length increase, the amount of reinforcement required to resist the bending stresses also increases. Therefore, the minimum diameter core must also increase to accommodate the extra reinforcing.
The cost of removing cores from casting cavities may become prohibitive when the areas to be cleaned are inaccessible. The casting design should provide for openings sufficiently large to permit ready access for the removal of the core.
Machining
Tolerance refers to the dimensional accuracy achievable for a given production method. For the green sand casting process, mold expansion, solidification shrinkage, and thermal contraction all influence the tolerance of the finished part. Consequently, there are limits for tolerances in an as-cast part. Subsequent machining is commonly employed when a tighter tolerance is required.
In the final analysis the supplier foundry is responsible for giving the designer a cast product that is capable of being transformed by machining to meet the specific requirements intended for the function of the part. To accomplish this goal a close relationship must be maintained between the customer’s engineering and purchasing staff and the casting producer. Jointly, and with a cooperative approach, the following points must be considered:
The casting process, its advantages and its limitations.
Machining stock allowance to assure clean up on all machined surfaces.
Design in relation to clamping and fixture devices to be used during machining.
Selection of material specification and heat treatment.
Quantity of parts to be produced.
It is imperative that every casting design, when first produced, be checked to determine whether all machining requirements called for on the drawings may be attained. This may be best accomplished by having a complete layout of the sample casting to make sure that adequate stock allowance for machining exists on all surfaces requiring machining. For many designs of simple configuration that can be measured with a simple rule, a complete layout of the casting may not be necessary. In other cases, where the machining dimensions are more complicated, it may be advisable that the casting be checked more completely, calling for target points and the scribing of lines to indicate all machined surfaces.
For more details on this subject, the Steel Founders’ Society of America (SFSA) produces a great primer on specifying steel castings that is worthy of further review.
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The outsourcing of plastic injection molding has become very commonplace, but it is not always as successful as hoped for. The strategic planning of your offshore outsourcing will make all the difference in your attempt to gain new business and develop new products.
Here are some of the successful plans global companies are using that really work. By utilizing these ideas, as they fit your unique needs, you can develop a strategy to not only survive in today’s extremely competitive international market, but thrive.
Those companies that are flexible and willing to adapt, often discover that entering into the global market reveals new opportunities for growth and profit. Global technology is a reality that can be used to your advantage.
Combine domestic and global technology to win contracts
Very often, plastic injection molding contracts are presented as a “package.” This can vary in it’s size and structure, but for our purposes, let’s use the following example:
Your molding or mold making company has an opportunity to bid on a new product that requires the building of eight plastic injection molds. You already know that other companies are bidding on the job, and they use offshore outsourcing to lower their costs.
Because you have wisely found several reliable, high quality offshore suppliers for injection molds, you are able to combine your resources to effectively quote the job. You can win in the global market by being flexible and using proven strategies.
Finding such an offshore source can be time-consuming and expensive, if you take it up on your own. The companies listed on this site are all known for their integrity, high-quality and pricing.
A very effective strategy
After a close examination of each job and how it fits in with the overall package, you determine that you will break up the eight molds as follows:
Keep the complicated work in-house
Send the simple, less risky work offshore
Split up the rest by deadline and level of expertise required. Send the easy part of the remaining difficult work offshore, such as simple cores and cavities, and manufacture the difficult parts in-house.
How does this benefit your company?
Spreads your risk out
You develop a working relationship with your offshore suppliers and work out the communication bugs and technical bugs.
You save approximately 35%
You can get more work done without hiring additional staff that you probably couldn’t find anyway!
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Tags: Injection, Molding, Outsourcing, Plastic
Les Klar talks about how attending an RJG Medical Symposium gave UPG fresh ideas on exceeding their customers expectations.
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Are you looking to bind half letter sized documents (8.5″ x 5.5″)? If you have looked around at the binding machines and binding supplies that are available on the market you have probably noticed that most of the equipment and supplies are designed for binding documents on the 11″ edge. Even so, if you are looking to bind half sheet books on the 8.5″ side there are a number of options available. Here are some of the things that you will need to consider if you are looking to bind half letter sized documents…
You will need to make sure that you have a binding machine that is capable of punching holes on the 8.5″ side of a piece of paper. In order to accomplish this you will most likely need to disengage a die so that you aren’t left with a half a hole on the edge of your paper. Many binding machines have disengageable dies to make this possible. However, some machines don’t and if you are planning on binding half letter sized documents (or landscape documents) you will need to make sure your machine has this capability.
After ensuring that you have a binding machine that is capable of punching an 8.5″ length you then need to find a binding spine that is 8.5″ in length. Here are some of the options that are available if you are looking for 8.5″ binding spines.
Plastic Comb Binding Spines are readily available for binding 8.5″ lengths (15 rings).
Spiral Coils can be ordered in 9″ lengths or can be cut down from standard 12″ lengths.
Twin loop wire can be ordered for half sized books or can be cut down from standard 11″ lengths using a small pair of wire cutters.
Hot knife Velobind strips are available in 8.5″ lengths for use with the Velobind system one, Velobind system Two and Velobind System Three Binding machines.
GBC Proclick and GBC Zipbind Binding Supplies can be cut down to 8.5″ using a sharp pair of scissors.
Finally, after ensuring that you have a binding machine that can punch the 8.5″ length and a binding spine that is 8.5″ long you will need to make sure that you have binding covers and paper that is the correct size for your project. Clear binding covers and opaque binding covers are readily available on the market for the 8.5″ x 5.5″ size. However, finding 8.5″ x 5.5″ paper can be slightly more difficult. If you have a high quality paper cutter you can cut the paper yourself. Otherwise, half size paper will have to be special ordered (it is available from Mybinding.com).
Some individuals choose to print pages for their half sized books 2 up on a page and then cut them afterwards. Others choose to use pages that are already 8.5″ x 5.5″. Either way, binding half sized documents isn’t that difficult and they tend to be ideal for training manuals, users guides, cookbooks and more.
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The latest offering from Audi in the coupe version is the Audi A5. This car is available with two engine sizes. The first is the 3.2 FSI engine. This is a 3.2L V6 engine with 265 horsepower and FSI direct injection. This fuel injection system works to electronically manage the engine to get it to work at varying degrees of power. Fuel injection is as the name suggests, the fuel is injected into the engine, where it is mixed with air and then combusted. Fuel injectors replaced the old carburetor system. Note there seem to be different versions of spelling the word carburetor. Fuel injectors are more precise with how much fuel is combusted, giving you better performance from your car.
The other engine size available is the 4.2 FSI engine. This 4.2L V8 engine works with 354 horsepower and also uses FSI fuel injection. The 4.2L refers to an engine size of 4,200cc, which is a large engine for a road car. Coupled with 354 horsepower, then the A5 makes for a powerful road car. The V8 refers to 8 cylinders in the shape of a V. The popular school of thought is that a V8 engine is more efficient in terms of driving power to the wheels from the combustion process, than a straight engine. Though of course using a straight engine of 8 cylinders will take up a lot of space under the bonnet..
The Electronic Stabilization Program [ESP] is a standard feature on the A5. ESP works to identify the direction and response that the car is going and then translates this motion into the wheels. What this means to the driver is better control of the vehicle in all conditions. The Servotronic steering is another popular feature of the A5. This creates different levels of servo assist in steering according to the speed of the car on the road.
The interior of the A5 is designed with comfort in mind. The seats contain full leather fabric and unique aluminium inlays. The car also has a three zone climate control system that works to create individual climate levels in the two halves of the front and also one area in the back.
An advanced anti-theft system is employed by the A5. A theft deterrent light is used in the driver’s door. What’s more the immobiliser keeps the car from starting when the wrong key is used. The electronic code in the car key must match the code used for the car before it will start.
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Plastics Injection molding application using KUKA robots. More information at www.kukarobotics.com.
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Tags: Injection, Machines, Molding, Plastic
This video is an excerpt from our Twin Screw Extruder Course – Lesson 1: Parts and Operation. This program provides training on the fundamentals of compounding with a twin screw extruder, including parts and operation, raw materials used, plastic behavior, optimizing controls, safety and startup procedures, troubleshooting and more. Employees will become experts in the startup, operation, and shutdown of twin screw extruder, with emphasis on maximizing productivity, safe operating procedures and quickly solving problems. Paulson Training Programs – Complete Training Solutions for the Plastics Industry. Visit www.paulsontraining.com for state-of-art plastics training, including interactive CD-ROM and online training.
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