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Green Sand Castings


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With over 6 decades of experience in green sand casting, Plymouth Foundry manufactures small components weighing 1 oz as well as complex parts up to 150 lbs in weight. Typical ASTM-grade casting materials that we use in our sand casting process include austenitic ductile iron, ductile iron, and gray iron. Available with tensile strengths from 20,000 psi to 100,000 psi, our high quality casting materials are suited for manufacturing general engineering parts that require high strength and wear resistance as well as pressure containing parts used in low temperature service environments.

Through spectrometer analysis and automatic nodularity testing, Plymouth Foundry inspects the quality of casting materials with ASTM specifications, prior to pouring. With in-house Brinell testing capabilities, we also verify material hardness for specific applications. Using recyclable sand molds, we manufacture custom sand cast parts up to 28" in length, 28" in width, and 14" in height. Mold sand quality is consistently controlled using a Hartley Sand Control system. We produce parts highly cored from shell, and isocure sand as well as parts without core.

Our green sand casting foundry is equipped with an automated sand delivery and mold handling system. The FBO-III Roberts Sinto Flaskless automatic molding system allows us to run castings that fit in a 20" x 24" flask and can be run with a maximum height of 8" in both cope as well as drag. The equipment regulates mold hardness consistency to minimize parting lines and core flashing, which in turn reduces your secondary finishing costs.

To store custom-built patterns, we maintain a separate storage facility built with fire-resistant wall panels and a sprinkler system. Plymouth Foundry’s green sand molding facility also includes Rota-lift molding machines. All melting takes place in two 4,000 lb capacity coreless induction electric furnaces. After cooling, we process the castings in a cleaning room fitted with grinding stations and spinner blast equipment.

Repairs, mounting, gating and rigging of tooling are performed in our pattern shop. We can also work closely with a number of outside tool makers to create or modify patterns and coreboxes to your specifications.





Specifications  · Equipment Used  · Quality Control

Specifications

General Capabilities

Furnish castings to customers’ specific requirements

Industry Focus

Agricultural
Appliance

Building

Construction

Electrical

Energy

HVAC

Industrial

Marine

Medical

Military/Mil-Spec

Mining

Railroad

Intended Application

Architectural
Automotive and Machine Components

Compressors & Expanders

Construction Machinery

Crankshafts

Engineered Plumbing

Engines

Gears

General Machinery

Heavy Compressors

Hydraulics

Impellers

Industrial Machinery

Light Compressors

Machine Tools

Medium Gear Blanks

Municipal and Water Works

Ornamental

Pumps

Rollers

Street Lamp Posts

Valves

Industry Standards

(We can meet unique specifications of customers)
ANSI

ASME

ASTM

ISO 9001:2000

Mil-Spec

Pressure Equipment Directive (PED) 97/23/EC 7/2, Annex I, Paragraph 4.3

Materials Poured

Austenitic Ductile Iron
  • ASTM A571-71
Ductile Iron
  • ASTM A536-84
Gray Iron
  • ASTM A48-83
High Silicon High Moly Ductile Iron

Tensile Strength (Castings)

20,000 psi to 100,000 psi

Casting Process

Green Sand Casting Process

Production Volume

From 1 unit to several thousand units per run
Low Volume to Mid Volume

Short to Medium Runs & Prototypes

Lead Times Available

4 weeks
Quoted on job by job basis

Casting Features

High Tensile
Thin Wall

Wear Resistant

Additional Services Provided

Assembly
E-Coating

Heat Treating

Inspection

Layout

Machining

New Pattern Equipment Procurement

Painting

Pattern Repair, Mounting, Gating, & Rigging

Software Used

Cimatron
SolidWorks

File Formats

2-D Vector
ASCII

AutoCAD (DWG,DWZ)

BMP

CADL

Catia (CATDrawing,CATPart)

CGM

DWG

DXF

EMF

FAX

GE33.1

GEO

GEO33.21

GIF

HGL

IGES

Inventor (IDW, IPT)

JPEG

NFL

OBJ

PARASLD

PCT

PCX

PDF

PLT

PNG

Pro-E or Pro/Engineer (DRW,PRT,XPR)

RAS

SAT

SFX

SolidEdge (DFT)

SolidWorks (SLDPRT,SLDDRW,SLDDRT)

STEP

STL

SurfCam (DSN)

SV

TGA

TIFF

TXT

VDA

WMF

WRL

Weight Range

1 oz to 150 lbs


Equipment Used

Molding Department

FBO-III Roberts Sinto Automatic Molding Machine (Flask Size: 20" x 24")
Rota-lift (Flask Sizes: 26" x 26" and 30" x 30")

Melting Department

2 - 4,000 lbs Coreless Induction Electric Furnaces

Core Types

Disco 3100 Isocure
Shell Sand

Cleaning Department

1 - Wheelabrator
1 - Spin Blast

2 - 30" Grinding Stations

4 - Secondary Grinding Stations

Pattern Storage Facility

Concrete building with a sprinkler system & fire walls separating pattern storage building from foundry.


Quality Control

Quality Objectives

  • Continuous improvement process that improves customer satisfaction and eliminates waste
  • Understand the quality expectations of our customers, thereby improving customer satisfaction
  • Deliver defect-free products to our customers on time
  • Continually train our employees in quality related matters
  • Develop quality improvement plans with our key customers and suppliers

Quality Control Capabilities

  • When we receive your order, a barcoded shop card featuring digital images is created, and all pertinent details are programmed into our Manufacturing Process Control system. As your order progresses through our shop, each department has detailed instructions to ensure that your parts are made to the proper specifications.
  • This system documents each step in the casting process, allowing us to determine the exact cost for each part and pass the savings on to you.
  • Our Hartley Sand Control system enables us to regulate the characteristics of the sand used in the molding process.
  • We utilize advanced technologies to see that you receive what you ordered. Spectrometer analysis and automatic nodularity testing ensure conformance to your specification and traceability by part number, heat code, and ladle. Brinell testing verifies hardness per specifications.
  • A Melt Analysis module allows us to keep detailed records of the chemical and physical properties of the metal we pour.
  • Computer tracking of in-house scrap promotes pro-active continuous improvement to meet quality requirements.
  • A special Corrective Action module in our manufacturing software package gives us the capability of following through on problems to see that they are resolved promptly and efficiently.
  • Our cutting edge production scheduling program module allows us to deliver both cast and machined parts on-time.
  • The bar-code order tracking system we use tells us within seconds where your order is in either the casting or machining divisions. This allows us to meet promised delivery dates, and you to schedule your production runs with the assurance that your castings will arrive on time, eliminating idle machines and costly downtime.


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