The process of greensand molding and pouring aluminum for Phillips Patterns. this is an 100% reclaim and recycle sand system. Music: Maxzwell - Amapola
Thanks for the upload. A couple of questions though, at 4:54 what is the purpose of the buttons and later in the video the hose attached to the match plate, is that a rapping device to help release the match plate from the sand?
Hi Garen, yet another interesting video for those of us into Casting Porn. ;)) I found it a bit strange that the castor paused during the cast and then topped off the various risers. I would have thought that it would be better to keep pouring till the risers were full, but then again I am only learning casting. I really liked the way the trolleys for the flasks to ride on utilise an under the floor loop system, a lot of thought went into that system, making for minimal effort by the boys on the shop floor. What sort of greensand mix are they using? IE % of Bentonite clay to sand and any extras? At what point does it become more efficient to use dies casting over greensand casting? Mark from Melbourne, Australia.
Couldn't tell you without asking the deck guys specifically but they definitely pause for a reason. Someone probably tested the castings and figured out that's the best way to pour them. Our guys do a lot of experimenting with new patterns to get the best castings possible. That's why its more art than science, sometimes you do thing that don't make sense but the finished part ends up being better regardless. Can't tell you the sand mix either. It's something my grandfather and father have worked on since the 50's and put a lot of work in perfecting. I can tell you we use two types of clays in our mix. As for die castings it depends on the size of the casting and how long it takes to cast and machine one. Smaller parts with high volume are typically die cast work, Dies become exponentially more expensive the bigger the casting. This C frames take 20 minutes on the CNC mills and Tippmann is increasing their orders at a rate we can't produce with sand casting so the next logical step is die casting. Once the new machine is up and running I'll probably do a video over when to switch from greensand to die cast and I'll showcase the new Die for these castings.
Lots of interesting information there, Garen, and I am definitely looking forward to your video on the Tippmann die. Interesting that the dies get exponentially more expensive as they get bigger, which I guess helps explain the continued use of greensand casting for things like car and truck engines.
I'm surprised the pouring flasks aren't pre-heated prior to dipping into the furnace. Do you hold the aluminum at 1400 degrees for long and if so, do you have any gas porosity problems?
Our machine shop manage of 15 years left us and I had to take over running the CNC shop and that pretty much consumed every minute i had for about 3 years. Had to put all my video stuff on the back burner. I actually quit to start this youtube channel and dedicate my time to making these videos, hoping it pays off cause I'm surviving on savings right now lol.
Damn, wish it could have been something simpler for you like getting busted for a meth lab or getting rid of an annoying employee. Getting your own life back....well that's just tough now a days. Fortunately you have the experience, connections, and resources to get you where you want to be. Just be ready for some long hours....But they are for you now...
myaabe we call them C frame, they're a leather stitcher for saddle repair. Invented by the founder of Tippmann Paintball. You see them briefly in episode 004, D1 Mold and tool
