Effort Foundry IncTechnology is the buzzword heard around the foundry today

NEW TECHNOLOGY OVERVIEWEFFORT FOUNDRY IS MAKING HUGE INVESTMENTS INTO NEW

TECHNOLOGY AS A PART OF OUR CONTINUOUS IMPROVEMENT PROGRAM TO BETTER SERVE OUR CUSTOMERS

• PRECISION MACHINING

• SOLID MODELING

• SOLIDIFICATION SIMULATION

• MACHINING SIMULATION

• 3D LASER SCANNING

• LASER MARKING

• ADDITIVE MANUFACTURING3D printing is currently outsourced with plans in place for it to be added to in-house capability

IN-HOUSE MACHININGTECHNOLOGY OVERVIEW

• VERTICAL TURNING

• HORIZONTAL TURNING

• HORIZONTAL MILLING

• VERTICAL MILLING

• KEYWAY CUTTER

• COMPETENCIES

• ROUGH MACHINING CASTINGS

• FINISH MACHINING CASTINGS

• PATTERNS AND PATTERN COMPONENTS

• BENEFITS

• VALIDATE CASTING QUALITY

• LOCATE AND UPGRADE SHRINK, INCLUSIONS, CRACKS, ECT…

• VALUE ADDED SERVICE TO CUSTOMER

• ONE STOP SUPPLIER

• DELIVERY

• FASTER REACTION TIME

• MACHINING ON CUSTOMERS SCHEDULE

VERTICAL TURNING WITH MILLING

• ROUGH & FINISH MACHINING• PART DIAMETERS UP TO 40”• PART LENGTHS TO 35”• MILLING ON TOP AND SIDE• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER

VERTICAL TURNING WITH MILLING

• TURNING• MILLING• DRILLING• TAPPING• TOP FEATURES• SIDE FEATURES

HORIZONTAL MILLING• ROUGH & FINISH MACHINING• (2) ROTARY DEVICES FULL 5 AXIS • X TRAVEL 40”• Y TRAVEL 30”• Z TRAVEL 25”• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER

HORIZONTAL MILLING• MILLING• DRILLING• TAPPING • MACHINING ON 5 SIDES IN ONE HOLDING

VERTICAL MILLING• ROUGH & FINISH MACHINING• X TRAVEL 30”• Y TRAVEL 20”• Z TRAVEL 20”• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER

VERTICAL MILLING• MILLING• DRILLING• TAPPING

HORIZONTAL TURNING• ROUGH & FINISH MACHINING• PART DIAMETERS UP TO 40”• PART LENGTHS TO 60”• MILLING ON FRONT AND SIDE• TOLERANCES TO .0002”• AUTOMATIC TOOL CHANGER

HORIZONTAL TURNING• TURNING• MILLING• DRILLING• TAPPING• FRONT FEATURES• SIDE FEATURES

KEYSEATER• KEYWAYS FROM 1/16” TO 1-1/2” WIDE

• UP TO 12” LONG

Solid Modeling and SimulationTechnology Flowchart

3D Model Parts

from 2D

Solidification Simulation

3D PrintedPlastic

CAM

SolidWorks

Create Machine Tool

G-Code

3D Model Patterns from 2D

Verify Casting Process

Verify Heat Treat

Process

Complex Pattern

Components

Complete Patterns

Rough and Finish

Machining of Castings

Machining of New Patterns

Verify Material

Stress

3D ScanningTechnology Flowchart

3D Scanner

Solidification Simulation

Assemble 3D Mold

Scan Casting

Scan Pattern

Solidworks

Solidworks 3D Model Casting

InspectPattern

CAMESPRIT

Inspect Casting

Dimensional Reporting

Dimensional Reporting

Laser MarkingTechnology Flowchart

Rough Machined

Effort Foundry

EFI Vendor

Customer

Laser Marker

Permanent Part

Identification

Finish Machined

In-house Part

Verification

Part ID for Outside

Processing

Completely Customizable Per

Customer Requirements

Part #Heat #

Pattern #Material

Part #Heat #

Pattern #Material

Additive Manufacturing (3D Printing)Technology Flowchart

3D printing is currently outsourced with plans in place for it to be added to in-house capability

PatternsComplex

Geometry

3D Printing

3D Printed Pattern

Components

Molds& Cores

Complex Geometry

3D Printed Complete Patterns

3D Printed Molds &

Cores

Plastic

Sand

Complete Parts

Complex Geometry

3D Printed Parts

MetalCurrently In Research &

Development Dept

Measure Pattern3D Scan

Model in Solidworks

Import to ProCast Simulate

Fail

Pass

Ready to Mold

Modify Model in

Solidworks

3D Scanning

3D Scanning

For Inspection

3D Printing In

EffortFoundry

Model Casting in Solidworks

Model Rigging in Solidworks

Import to ProCast Simulate

Fail

Pass

Ready to Mold

Modify Model in

Solidworks

Model Finished

Machined Part in

Solidworks

Model Adding .06 to

Finished Surfaces

Model the As-Cast

for Material Removal

Ready for Machine

Shop

In-house Drawings

made and

checked

Create Toolpathfor Rough and Finish

Model Finished

Machined Part in

Solidworks

Model Adding .06 to

Finished Surfaces

Model the As-Cast

for Material Removal

In-house Drawings

made and

checked

Create Toolpathfor Rough and Finish

Rough Machine

to Drawing

NDT and Upgrade

Ready to Ship

Finish Machining Required?

No

YesFinish

Machine to Drawing

Final Dimensional Verification

Validate Casting

“Baseline”

Validate Casting

“Baseline”

Rough Machine

to Drawing

Finish Machine

to Drawing

Patterns Too!