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- Title
RE-EVALUATING CORE DIMENSIONAL CHANGES.
- Authors
Showman, R.; Nocera, M.; Madigan, J.; Baltz, G.; Hajduk, T.; Wohleber, J.
- Abstract
Ford Motor Company's Cleveland Casting Plant experienced unexpected dimensional changes on gray iron cylinder block castings as measured at the engine plant. The casting plant formed a Statistical Weapons and Tactics (SWAT) team to address the issue. The team generated volumes of background data but failed to fully identify the root causes. Measurements of the waterjacket core showed that dimensions decreased or shrank over time and with different processing changes. While the amount of shrinkage was very small compared to the overall dimensions of the block, the mechanism was not well understood and hereto had not been factored into tooling dimensions. A project was initiated with Ashland Casting Solutions, their binder supplier, to compare the effects of different materials and process variables on coldbox core shrinkage. Measurement methods were analyzed and Design of Experiments (DOEs) were conducted to measure the shrinkage of cores produced with different materials under various conditions. Additional testing was conducted to investigate the effects of postcoremaking operations like coating, drying, and storage under varying conditions. These results were included with those from other investigations to modify core tooling and resolve the issue at the casting plant.
- Subjects
CLEVELAND (Ohio); OHIO; FORD Motor Co.; METAL castings; EXPERIMENTAL design; EXPANSION &; contraction of concrete; FOUNDRY research; FOUNDRY equipment
- Publication
International Journal of Metalcasting, 2010, Vol 4, Issue 3, p63
- ISSN
1939-5981
- Publication type
Article
- DOI
10.1007/BF03355498