CR Masterclass 3 - World Class GET Manufacturing
Summary
TLDRJames 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
🏭 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.
🔍 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.
🛠 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.
Mindmap
Keywords
💡Casting
💡Magma Software
💡CNC Machining
💡Additive Manufacturing
💡Furane Resin System
💡Electric Arc Furnaces
💡Clean Steel Technology
💡Heat Treatment
💡Metrology
💡Non-Destructive Testing (NDT)
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
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