Understanding the Trial and Sample Process for Castings

Trial casting

Whenever a new product or item is to be cast, there will be either an existing part or a drawing which shows the dimensions and material specification (which grade of iron is required) of the part.

There is a need to ascertain the design needs such as pattern shrink allowance, molten metal flow, mechanical properties of the finished product, required surface finish, metal grain structure etc. This would call for creating a trial run of the castings from the tooling to match all the material and finish specifications for testing the parameters. Chemical and physical testing of the trial piece would then determine if in fact all of the parameters had been met. spam tools

Pilot Sample

Any time new tooling is created, a pilot sample should be produced to ascertain the quality of the product – prove out that the tooling and configuration of the part works. The sample needs to be measured against the original casting or drawing, and a summary of these findings created. This sample may go through a battery of destructive and non-destructive tests to assess the likely flaws in it and to decide on corrective measures for the repeat castings. Machining and any other surface finished should also be completed in order to view an actual completed part. spamming tools

The pattern, core and mould designs could get changed accordingly to achieve desired results and improved quality.

Sample Approval

The customer and Foundry may find that no changes are required before a production run. The customer would then complete internal paperwork or use the Foundry’s forms to advise that the samples are acceptable and that production orders can be produced. php mailer

Another scenario that can arise is that the customer will approve the samples, based on certain changes being made during a production run – perhaps for the finishing required in the Foundry on their part, ie. more or less grinding.

The Sample and Sample Approval process can take from as little as 2 weeks to 3 months or longer, depending on the amount and complexity of any post processes that the castings go through, and the importance placed on this approval by the customer. SmartSerialMail

After Sample Approval

Random checks should be completed on the tooling to ensure future production runs meet the quality and dimensional specifications that were arrived at during the Sampling process. These type of checks will depend on how frequently each part / tooling is run, and may be part of an internal Quality process. UNLIMITED SMTP

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