CR Masterclass 3 - World Class GET Manufacturing

Summary

James De Ru, Operations Manager at CR Mining's Maryborough Foundry in Australia, presents a master class on maximizing cast lip and GT manufacturing. The foundry, with over a century of history, specializes in producing high-quality castings for excavators and other heavy machinery. Leveraging cutting-edge technologies like Magma software for casting simulation and additive manufacturing for pattern making, the facility ensures optimal production processes. The video highlights the importance of steel making, heat treatment, and non-destructive testing in achieving world-class castings that meet stringent quality standards.

Takeaways

• 🏭 James Deru, Operations Manager at CR Mining's Maryborough Foundry, presents a master class on maximizing cast lip in GT manufacturing.
• 🌟 The foundry has a rich history of over 100 years and specializes in producing high-quality GT and car slips for over 40 years.
• 💹 CR Mining has made significant investments in state-of-the-art technologies to ensure future production excellence.
• 🔩 The facility manufactures a wide range of car slips, from small excavators to the largest 800-ton excavators, wheel loaders, rope shovels, and drag lines.
• 👨‍🔬 The site employs 112 personnel, including foundry specialists such as methods engineers, metallurgists, and welding engineers, who are crucial for consistent high-quality castings.
• 🔧 The manufacturing process begins with casting simulation using Magma software to optimize the casting process and identify potential defects.
• 🛠️ Patterns are produced by CNC machining and additive manufacturing technologies, like 3D printing, to provide tight dimensional tolerances and rapid results.
• ⚙️ On-site, a hard sand process using the furane resin system is employed, along with automated core blowers for producing cores.
• 🔩 CR has invested over 1.5 million dollars in mold and core making capabilities, enhancing the quality and efficiency of casting production.
• 🔥 Steel making is a critical step, with two electric arc furnaces used for special refining processes to ensure high-quality steel for castings.
• 🛡️ Advanced steel analysis techniques, including optical emission spectrometers and hydrogen analysis, are used to ensure steel meets strict specifications.
• 🌡️ Post-steel making, molten steel is poured into sand molds and later heat-treated in gasified stoves to modify the steel's microstructure for optimal mechanical properties.
• 📏 Gauging and dimensional assessments, or metrology, are critical for quality assurance, ensuring all components fit smoothly and safely in the field.
• 🔎 Non-destructive testing (NDT) techniques such as magnetic particle inspection (MPI), ultrasonic testing (UT), and hardness testing are employed to assess casting quality and compliance.

Q & A

Who is the speaker in the video and what is his role at CR Mining's Maryborough Foundry?

The speaker is James Deru, who is the Operations Manager at CR Mining's Maryborough Foundry.

What is the main topic of the master class presented by James Deru?

The main topic of the master class is how to maximize cast lip in GT manufacturing for customization needs.

How long has CR Mining's Maryborough Foundry been in operation?

CR Mining's Maryborough Foundry has over 100 years of history.

What types of equipment does the foundry produce?

The foundry produces a range of equipment including GT and car slips, excavators, wheel loaders, rope shovels, and drag lines.

What is the significance of the personnel employed at the site?

The site employs 112 personnel, including foundry specialists such as methods engineers, metallurgists, and welding engineers, who are essential for producing consistent high-quality castings.

What software does CR use for casting simulation and why is it important?

CR uses Magma software for casting simulation to optimize the casting process and identify possible defects like shrinkage and hot spots, ensuring optimal manufacturing solutions.

How does CR Mining's foundry ensure tight dimensional tolerances in pattern production?

CR employs CNC machining for pattern production, which allows for the tightest dimensional tolerances and can be completed on different pattern materials.

What is the role of the hard sand process in mold and core production at the foundry?

The hard sand process using the furane resin system and various types of sands is used to provide different mold properties, and cores are produced on automated core blowers.

How does CR Mining's foundry ensure the quality of steel used in castings?

The foundry uses electric arc furnaces for steel making, allowing for special refining processes to remove impurities and gases detrimental to steel quality.

What technologies does the foundry use to assess the steel quality and ensure it meets specifications?

The foundry uses optical emission spectrometers, including a market-leading ISPAC 8820, and a hydrous unit for hydrogen analysis to ensure steel quality.

How does the foundry enhance the steel quality after it is tapped into the pouring ladle?

The foundry employs clean steel technology, which involves the induction injection of calcium wire and purging with argon gas to remove and modify inclusions in the steel.

What is the purpose of heat treatment in the casting process at CR Mining's foundry?

Heat treatment is used to modify the microstructure of the steel to provide the final mechanical properties, which is essential for producing high-quality castings that meet customer needs.

How does the foundry ensure dimensional accuracy and compliance of castings?

The foundry uses state-of-the-art metrology equipment, such as 3D scanners and furrow arms, to measure critical dimensions and ensure castings are compliant with tight dimensional requirements.

What non-destructive testing (NDT) techniques are employed to assess castings for defects?

NDT techniques such as magnetic particle inspection (MPI), ultrasonic testing (UT), and hardness testing are used to assess for defects and validate heat treatment compliance.

Outlines

00:00

🏭 Introduction to CR Mining's Maryborough Foundry

James Deru, Operations Manager at CR Mining's Maryborough Foundry in Queensland, Australia, introduces a masterclass on maximizing cast lip in GT manufacturing. The foundry, with over 100 years of history, specializes in producing GT and car slips for over 40 years. CR Mining has invested in state-of-the-art technologies and employs 112 personnel, including specialists like methods engineers, metallurgists, and welding engineers. The manufacturing process begins with casting simulation using MAGMA software to optimize casting processes and identify potential defects. Patterns are produced by CNC machining or 3D printing, and the foundry uses a hard sand process with various sands to create molds and cores. CR has also invested in mold and core making capabilities, ensuring quality castings, efficient manufacturing, and fast delivery.

05:02

🔍 Steel Making and Quality Assurance at CR's Foundry

The paragraph discusses the critical role of steel making in achieving the final quality of castings. CR's Maryborough foundry uses electric arc furnaces for special refining processes, removing impurities like phosphorus and sulfur, and gases like hydrogen and nitrogen. The foundry employs various analysis techniques, including optical emission spectrometers and a hydrous unit, to ensure steel quality meets strict specifications. Clean steel technology is used post-steel making to enhance steel quality further. Molten steel is poured into sand molds and, after solidification, is subjected to heat treatment in gasified stoves to achieve the desired mechanical properties. The foundry also uses metrology equipment for dimensional assessments to ensure castings fit smoothly and safely in the field, minimizing downtime and maintenance costs.

10:04

🛠 Post-Processing and Quality Control at CR's Foundry

This section covers the post-casting processes and quality control measures at CR's foundry. After steel castings are removed from sand molds, risers are removed, and the castings undergo heat treatment in large gasified stoves to modify the microstructure and achieve the final mechanical properties. The foundry employs state-of-the-art heat treatment facilities to optimize the mechanical properties of castings, ensuring they are fit for purpose and can withstand harsh operating conditions. Gauging and dimensional assessments are critical for quality assurance, with 100% of fit areas on lips and GT components being gauged to maintain tight casting tolerances. Non-destructive testing (NDT) techniques like magnetic particle inspection (MPI), ultrasonic testing (UT), and hardness testing are used to assess castings for defects and ensure compliance with specifications, guaranteeing world-class quality and durability.

Keywords

💡Casting

Casting refers to the manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. In the context of the video, casting is the primary method used to produce large excavator parts such as GT and car slips. The video mentions the use of state-of-the-art casting facilities and technologies to ensure high-quality castings, highlighting the importance of this process in manufacturing world-class products.

💡Magma Software

Magma Software is a type of casting simulation software used by engineers to optimize the casting process. It allows for fill and solidification modeling, which helps identify potential defects such as shrinkage and hot spots. In the video, CR Mining's foundry uses Magma software to design optimal processes for casting, ensuring that products are cast right the first time with the highest quality.

💡CNC Machining

CNC (Computer Numerical Control) Machining is a manufacturing process that uses computers to control machine tools for the production of parts. In the video, CR's foundry uses CNC machining to produce patterns with tight dimensional tolerances, which is crucial for achieving high-quality castings. The process can be completed on different pattern materials, showcasing the versatility and precision of CNC machining in the casting industry.

💡Additive Manufacturing

Additive manufacturing, commonly known as 3D printing, is a process of making three-dimensional solid objects from a digital file. The video mentions that CR employs additive manufacturing technologies for pattern making, which allows for specialist solutions and rapid results to meet customer needs. This technology is a modern approach to pattern making in the casting process, enhancing efficiency and innovation.

💡Furane Resin System

The Furane Resin System is a type of chemical binder used in the foundry industry for hard sand molding. The video describes the use of this system at CR's foundry, where multiple types of sands are used to provide different mold properties. This system is part of the hard sand process that contributes to the production of high-quality castings with desired properties.

💡Electric Arc Furnaces

Electric Arc Furnaces (EAFs) are used in the steel industry for the production of steel from scrap metal. In the video, CR's foundry has two EAFs with a combined pour weight of up to 23 tonnes. The use of EAFs allows for special refining processes, such as carbon boiling, which helps remove impurities from the steel. This results in a high-quality steel that is essential for the production of durable castings.

💡Clean Steel Technology

Clean Steel Technology refers to a set of processes aimed at improving the purity and quality of steel. The video describes the use of this technology at CR's foundry, where calcium wire is induction-injected into the molten metal while purging with argon gas. These processes help remove and modify inclusions in the steel, leading to enhanced mechanical properties in the castings and preventing in-service failures.

💡Heat Treatment

Heat treatment is a series of processes used to alter the physical and mechanical properties of materials. In the video, CR's foundry uses gasified heat treatment stoves to modify the microstructure of steel castings, providing the final mechanical properties required for high-quality castings. Heat treatment is essential for ensuring that the castings meet customer needs and have the necessary strength and durability for their intended use.

💡Metrology

Metrology is the scientific study of measurement and the establishment of measurement standards. In the context of the video, metrology refers to the gauging and dimensional assessments of castings to ensure they fit smoothly and safely in the field. CR's foundry uses calibrated gauges and state-of-the-art equipment like 3D scanners to measure critical dimensions, ensuring that castings meet tight dimensional requirements and avoid costly downtime.

💡Non-Destructive Testing (NDT)

Non-Destructive Testing (NDT) is a wide group of analysis techniques used in science and industry to evaluate the properties of a material, component, or system without causing damage. The video mentions that CR's foundry employs NDT technicians who use techniques like magnetic particle inspection, ultrasonic testing, and hardness testing to assess for defects and ensure compliance with specifications. These tests guarantee that the castings are of world-class quality and fit for purpose in their operating environments.

Highlights

CR Mining's Maryborough Foundry is a state-of-the-art casting facility with over 100 years of history.

The foundry has been manufacturing GT and car slips for over 40 years.

Significant investment in industry-leading technologies for future production.

Produces a wide range of car slips, from 100-ton to 800-ton excavators and other heavy machinery.

Employs 112 personnel, including foundry specialists like methods engineers, metallurgists, and welding engineers.

Casting simulation with MAGMA software optimizes the casting process and identifies potential defects.

Utilizes CNC machining and additive manufacturing for pattern making with tight dimensional tolerances.

On-site hard sand process with furane resin system for mold properties.

Investment of over 1.5 million dollars in mold and core making capabilities.

Two electric arc furnaces for steel making with special refining processes.

Use of optical emission spectrometers and hydrous units for steel quality analysis.

Clean steel technology with calcium wire induction and argon gas purging for enhanced steel quality.

Molten steel is poured into sand molds at over 1500 degrees Celsius.

Heat treatment processes with gasified stoves for modifying steel microstructure.

State-of-the-art metrology equipment like 3D scanners and furrow arms for dimensional assessments.

Non-destructive testing (NDT) techniques to assess for defects and ensure compliance to specifications.

Hardness testing after quenching temper processing to validate heat treatment compliance.

Tight control and management of manufacturing processes to ensure quality and durability of car slips.

Collaboration with site support specialists to unlock productivity and lower cost of ownership.

Transcripts

[Music]

my name is james deru i am the

operations manager at cr mining's

maryborough foundry based in queensland

australia today i'm going to be

presenting a master class on how to

maximize cast lip in gt manufacturing

for your customization needs

cr's maryborough foundry is a

state-of-the-art casting facility with

over 100 years of history

we have been manufacturing world-class

gt and car slips at the foundry for over

40 years

cr mining has invested significantly in

the facility to implement

industry-leading technologies to ensure

production of world-class castings into

the future the foundry produces a huge

range of car slips from small hundred

ton excavators up to the largest 800 ton

excavators wheel loaders rope shovels

and drag lines the site employs 112

personnel including on-site foundry

specialists such as methods engineers

metallurgists and welding engineers

these highly skilled and experienced

workers are essential to producing

consistent high quality castings

the manufacturing process at cr begins

with casting simulation

highly experienced methods engineers use

magma software to optimize the casting

process

this software allows for fill and

solidification modeling which identifies

possible defects such as shrinkage and

hot spots

in this way a optimal processes are

designed allowing for optimal

manufacturing solutions

consequently

we cast products right the first time

with the highest quality

once the casting methods have been

finalized patterns are produced by cnc

machining this process provides the

tightest dimensional tolerances and can

be completed on different pattern

materials such as timber toolboard and

aluminium as we are showing here

cr also employs additive manufacturing

technologies for pattern making such as

3d printing

these extensive pattern making

capabilities allow for specialist

solutions and rapid results to meet our

customers needs

on site we employ a hard sand process

using the furane resin system multiple

types of sands such as silica

chromite and zircon are used to provide

different mold properties

cores are produced on automated core

blowers using the coal box process

in this process sand is mixed with resin

and injected into the core box before

being purged with a catalyst gas

finally molds and cores are painted with

refractory paints enclosed ready for

pouring

cr has invested heavily in its molds and

core making capabilities with over 1.5

million dollars being spent on omega

molding and sand reclamation equipment

this equipment along with highly

experienced trade qualified molars

allows for novel approaches to molding

which translate to quality castings

efficient manufacture and fast delivery

steel making is possibly the most

critical step that contributes to the

final quality of a casting

at cr's maryborough foundry we have two

electric arc furnaces with a combined

pour weight of up to 23 tonnes

steel making in eafs allows for special

refining processes to be completed by

controlling slag compositions process

temperatures and the process known as

carbon boiling as a result impurity

elements such as phosphorus and sulfur

can be removed from the steel down to

very low concentrations

additionally gases such as hydrogen and

nitrogen which are extremely detrimental

to the steel are removed eaf melting

provides a huge quality advantage over

techniques such as induction

at the foundry we use several different

analysis techniques to assess the steel

quality ensure it meets cr's tight

specifications

to assess the chemical composition of

the steel optical emission spectrometers

are employed

on site we have two oes's one of which

is a market-leading ispac 8820

this unit has high-end capabilities such

as nitrogen assessment down to parts per

million concentration and inclusion

analysis software

we also employ a hydrous unit for the

analysis of hydrogen in the molten steel

this ensures that no castings are poured

without meeting tight limits on hydrogen

this is essential in high hardness gt

and fixed section cut lip castings where

hydrogen can be extremely detrimental

once the steel is tapped into the

pouring ladle we employ clean steel

technology to further enhance the steel

quality

this technology involves the induction

injection of calcium wire into the

molten metal while purging the steel

with argon gas

these processes have the combined effect

of removing and modifying inclusions in

the steel

the world-class steel making processes

and used by cr provide enhanced

mechanical properties in the castings

which prevent in-service failures

prevent maintenance downtime and extend

service life

after steel making is completed the

molten steel at over 1500 degrees

celsius is poured into sand molds using

bottom pore ladles

once solidified and cooled the steel

castings are removed from the sand molds

in a process known as knockout

after knockout the castings must have

the risers removed before on processing

this is completed using a knock-off

hammer with up to 28 000 joules of force

in the as-cast condition steel is

relatively brittle as a result steel

castings must be heat treated to modify

the microstructure of the steel to

provide the final mechanical properties

this is a key part of the manufacturing

process and is essential to produce high

quality castings that meet customer

needs

the foundry has five gasified heat

treatment stoves which are some of the

largest of their type in australia

they are capable of processing our

largest one piece cast lips and

maintaining a temperature uniformity of

plus or minus 10 degrees celsius

throughout the work zone

castings are treated with

proprietary heat treatment cycles with

full traceability of heat treatment

charts through the use of eurofirm

control software once the castings are

soaked for the appropriate time frame

they are cooled via water quenching in

one of our two quench tanks

huge agitators are fitted to the quench

tanks to ensure water flow preventing

vapor blankets and ensuring uniformity

of quench

the state-of-the-art heat treatment

facilities employed optimize the

mechanical properties of the castings

which prevent in-service failures

prevent maintenance downtime and upkeep

and extend service life of the cast lips

and gt

gauging and dimensional assessments also

known as metrology are critical steps in

the quality assurance process

they ensure all lip and gt components

fit smoothly and safely in the field

consequently changeout times for gt are

minimized and get retention is insured

100 of fit areas on lips and gdt are

gauged using calibrated gauges to ensure

the specified casting tolerances are met

tolerances as low as 0.5 millimeters are

maintained on large castings

guaranteeing field modifications which

impact downtime safety and labor costs

are not required

state-of-the-art metrology equipment

such as 3d scanners furrow arms are also

employed to measure critical dimensions

on castings

this further ensures cr castings are

compliant to the tightest dimensional

requirements this is essential to ensure

lip and gt all fit together safely and

easily avoiding costly downtime

highly experienced ndt technicians

employ multiple different techniques to

assess for defects in castings and

evaluate compliance to specifications

magnetic particle inspection

mpi is used to assess the surface

related casting defects

all gt and lip castings have 100 of the

cast surfaces tested to ensure castings

are free from non-compliant defects and

castings are of the highest quality

ultrasonic testing ut is used to assess

for subsurface casting defects ut

inspection is completed on high

integrity castings and on areas that are

exposed to high service stresses

hardness testing is completed after

quenching temper processing to validate

the heat treatment compliance

hardness testing is completed using both

king brunel and equitip lib test methods

on large castings such as lips multiple

hardness tests are completed to ensure

consistent

hardness across the casting

ndt testing guarantees that castings are

a world-class quality and fit for

purpose in the harsh environments they

operate in with huge forces they must

withstand throughout their service life

which for cast lips can be

over five years

all the steps of the manufacturing

process must be tightly controlled and

managed to ensure car slips meet very

demanding quality assurance

specifications

required to deliver strength and

durability through enhanced mechanical

and metallurgical properties

ease of on-site maintenance through

tight dimensional tolerances for smooth

and safe fitment and removal of gt

get the manufacturing phase correct and

you are ready to work with our site

support specialist to unlock that five

percent productivity and lower your cost

of ownership

thank you for your time today and back

to you gary

to

[Music]

you