top of page
This site was designed with the
.com
website builder. Create your website today.Start Now

TESTING

Introduction and Summary of Testing

​

The foundry flask punch out machine has several areas that will be tested. The machine is designed to press sand and castings out from an array of flask sizes. The machine has been designed to handle to loads with appropriate deflection requirements in addition to being ergonomic for the user. Both the functionality and physical properties of the machine will be tested. For testing the functionality, cycle times will be calculated for removing the sand. This test is a derivative of the build requirement that the machine was required to have a cycle time of less than 1 minute. In addition testing will be calculated on sand remove of different flask sizes. The requirement of removing 90% of sand from the flask with a single punch through of the arbor press ram is the requirement of concern.

 

Test 1- Flask Rail Deflection

 

INTRODUCTION

  • The flask rail deflection test is to measure how much the center of the back flask rail deflects when a flask is loaded with 2,000 lbf. A testing Jig and bottle jack were used to create this force. It is predicted that the flask rail will deflect .0012 inches. This predicted value was concluded from a uniformly loaded beam with fixed ends. Reference analysis sheet A-9.

 

METHOD & APPROACH

  • To perform this test a testing jig was created to mount to the column in replacement of the arbor press used. This was so a bottle jack could be used in conjunction with a Fluke load cell to accurately load the flask rails. Accuracy is limited by the deflections across the machine when loaded. This will affect the measurement of the rail deflection. The precision of this test will be limited by the magnetic dial indicator used to measure the deflection. This dial indicator is scaled in .001 inches with the accuracy of .0005” inches.  When loaded dial indicators were pictured so they could be reviewed at a later date. Data will be presented in a comparative analysis with the predicted value.

 

TEST PROCEDURE

  • Testing was completed on April 11, 2018. The test took 1 hour to setup and complete. The test was done in Central Washington University’s Power Tech Lab with the help from Matt Burvee, CWU Lab Technician. Resources needed were a Fluke Load cell with a computer to transmit data, a digital 0-200 lb. scale, a standard automotive bottle jack, a testing jig that provides attachment to the column and a surface for the bottle jack to press on, a standard steel 12”x18” foundry flask, and lastly a 1” thick 12”x18” (or greater) steel plate.

    • Step 1

      • Weigh and record foundry flask and steel plate.

    • Step 2

      • Bolt testing jig onto the column of the Foundry Flask Punch-Out machine

    • Step 3

      • Place the magnetic dial indicator on the machine frame at the front middle 2”x2” tubing cross member. Move the dial arm so the dial is perpendicular to the center of the back flask rail. Make sure the dial is reading within .5” of center on the rail.

    • Step 4

      • Center foundry flask on the machines rails and cover with the steel plate.

    • Step 5

      • Place bottle jack under the testing jig and place the Fluke load cell in between the bottle jack and steel plate.

    • Step 6

      • Center the load cell and bottle jack on the steel plate within .5” of center.

    • Step 7

      • Calculate the additional weight of the flask and plate and reduce it from the 2000 lb. load. Now a load value will be acquired to reach when loading the machine.

    • Step8

      • Apply the calculated load via bottle jack.

    • Step 9

      • Read and record the value shown on the dial indicator.

    • Step10

      • Repeat and record test 3 times and average the data

 

  • Technical Risk

    • The flask, steel plate, and testing jig have weights exceeding 40 lbs. Lift carefully and use a floor crane or lifting cart if needed. Do not place any body part in-between the bottle jacks loading surfaces when loading the jack.

 

 

Test 2 – Column Deflection

 

INTRODUCTION

  • In the design of the Foundry Flask Punch-Out machine the column was designed with a deflection requirement when a 2000 lb load was present on the arbor press used. At 16.25” from the baseplate the column was predicted to flex .014” in the perpendicular direction (reference analysis A-3).

 

METHOD & APPROACH

  • To perform this test a testing jig was created to mount to the column in replacement of the arbor press used. This was so a bottle jack could be used in conjunction with a Fluke load cell to accurately load the flask rails. Accuracy is limited by the deflections across the machine when loaded. This will affect the measurement of the column deflection. The precision of this test will be limited by the magnetic dial indicator used to measure the deflection. This dial indicator is scaled in .001 inches with the accuracy of .0005” inches.  When loaded dial indicators were pictured so they could be reviewed at a later date. Data will be presented in a comparative analysis with the predicted value.

 

TESTING

  • Testing was completed on April 11, 2018. The test took 1 hour to setup and complete. The test was done in Central Washington University’s Power Tech Lab with the help from Matt Burvee, CWU Lab Technician. Resources needed were a Fluke Load cell with a computer to transmit data, a digital 0-200 lb. scale, a standard automotive bottle jack, a testing jig that provides attachment to the column and a surface for the bottle jack to press on, a standard steel 12”x18” foundry flask, and lastly a 1” thick 12”x18” (or greater) steel plate

    • Step 1

      • Weigh and record testing jig

    • Step 2

      • Bolt testing jig onto the column of the Foundry Flask Punch-Out machine

    • Step 3

      • Place the magnetic dial indicator on a secure magnetic surface that is separate from the machine. Position the indicator so it is reading on one side of the column 16.25” from the base plate in a perpendicular position. 

    • Step 4

      • Center foundry flask on the machines rails and cover with the steel plate.

    • Step 5

      • Place bottle jack under the testing jig and place the Fluke load cell in between the bottle jack and steel plate.

    • Step 6

      • Center the load cell and bottle jack on the steel plate within .5” of center.

    • Step 7

      • Calculate the additional weight of the testing jig and add it to the 2000 lbf load applied by the bottle jack.

    • Step8

      • Apply the calculated load via bottle jack.

    • Step 9

      • Read and record the value shown on the dial indicator.

    • Step10

      • Repeat and record test 3 times and average the data.

    • Step 11

      • Reposition dial indicator to read perpendicular to the baseplate in line and within .5” in front of one column side.

    • Step 12

      • Repeat the previous load and record the distance the baseplate bowed upward.

    • Step 13

      • Calculate angle and deflection of column

 

  • Technical Risk

    • The flask, steel plate, and testing jig have weights exceeding 40 lbs. Lift carefully and use a floor crane or lifting cart if needed. Do not place any body part in-between the bottle jacks loading surfaces when loading the jack.

​​

​

Test 3 – Sand Removal Precentage

 

INTRODUCTION

  • The creation of the Foundry Flask Punch-Out machine was to increase the efficiency of removing foundry sands from flasks. It was predicted that the use of this machine on 12"x 14" flasks would remove 90% or more sand with a single punch out. 

 

METHOD/APPROACH

  • Testing the Foundry Flask Punch-Out machine requires there to be four 12" x 14" flasks that have been filled with compacted sand. The flasks are weighed 3 times during this test. Once before filling with sand, once filled with sand, and lastly once after a single punch out has occurred. This method will produced the sand removal rate in the form of a percent. 

 

TESTING

  • Testing will be performed on 5/8/2018. The testing will be done at Central Washington University's foundry located in the Hogue Technology building. Resources needed are four 12" x 14" flasks, green diamond olovine sand.  

    • Step 1

      • select, weigh, and record the mass of four different 12" x 14" flasks. 

    • Step 2

      • Mix green sand in the Muller to 4-10% moisture percentage.

    • Step 3

      • Compact the sand into the four flasks with a hand held ram. 

    • Step 4

      • Use a striker bar to clean the top of each mold so it is flush with the flask. 

    • Step 5

      • Weigh each flask and record its mass. 

    • Step 6

      • Punch out each of the four flasks on the Foundry Flask Punch-Out machine. 

    • Step 7​

      • Record the mass of each flask after punch out. ​

    • Step 8​

      • Calculate the sand removal percentage.​

  • Technical Risk

    • Care must be given to handling flask as they weigh more than 50 lbs. when loaded with compacted sands. Operation of the sand handling equipment must be done with someone trained and checked off on the equipment. 

DELIVERABLE/CONCLUSION

  • This test was successful. The Sand removal rate of the foundry flask punch out is approximately 92%. Variations lie within the sand compaction rate as well as the moisture content of the sand. 

​

​

bottom of page