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Case Study - Instrument trasnformer box and cover casting

instrument-trasformer-1280x724.jpg

The case study describes how Taroni Foundry, aluminum foundry, has succeeded in creating aluminum castings for Instrument transformer sector reducing costs compared to its low-cost competitors maintaining Europeans and Canadians quality requirements .

Taroni Foundry took full advantage from Co-design with the customer, the casting simulation and rapid prototyping for aluminium castings, able to comply with the strictest regulations in the energy sector.

Product

Casting instrument transformer box and cover

Objectives

Cost of finish part competitive with "low cost" Countries competitors

Customer Requirements

Liquid pressure test 2 bar (30 psi) and roughness 1,6 µm

The Challenges

• Cost of finish part competitive with “low cost” Country competitors
• Maintain the quality of European production
• Metal treatment must provide a well modified structure for mechanical properties as well as a melt free from inclusions and oxides
• Filling must be turbulence free to avoid creating fresh oxides in the die cavity
• Feeding must be efficient to avoid shrinkage

How we win the challenges

CO DESIGN

Specifications, product use, costs, quality, quantity are analysed with the customer. We also carry out an approximate analysis of the costs of the tools needed.

AUTOMATION FOUNDRY PROCESS

Thanks to the size of the machinery of the foundry it has been possible to realize a mold with two cavities with dimensions of 1200 x 1000.

CASTING SIMULATION

The casting simulation is a tool used in foundries to monitor the filling process of the aluminum into the mold, so check filling and solidification of castings and identify any critical areas.

AUTOMATIC MACHINING PROCESS

Technical Data Sheet

COVER

  • Alloy: Alloy 43300, T6 AL
  • Casting weight: 14 Kg (each one 2 cavity)
  • Pouring temperature: 760°C
  • Pouring weight: 50 Kg - Yield: 56%
  • Moulding Process: Gravity die casting
instrument transformer aluminium
instrument transformer aluminium
instrument transformer aluminium

BOX

  • Alloy: Alloy 43300, T6
  • Casting weight: 31 Kg (one piece)
  • Pouring temperature: 760°C
  • Pouring weight: 47 Kg - Yield: 56%
  • Moulding Process: Gravity die casting
instrument transformer aluminium
instrument transformer aluminium
instrument transformer aluminium

Casting Simulation

simulation castig
simulation castig
simulation castig
simulation castig

Simulation Benefits

  • Reduce time and cost of production
  • Compliance with quality standards required
  • Reduction of non-compliance
  • Optimization of feed channels
  • Evidence of pockets of stagnation and the areas exposed to the danger of entrapped air
  • Evidence of any “porosity”

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