CPM Industries' Blog

Tim Carlstedt

Recent Posts

Designing Tips for Heavy or Large Castings

Posted by Tim Carlstedt

   I wanted to take some time to discuss some aspects that need to be considered with Large, Heavy Castings.   We are going to provide some tips and discuss our thought process when working with these Large Sand Castings

Read More

Tags: Aluminum Sand Casting, Ductile Iron Sand Castings, Cast Iron (Gray) Sand Casting, Large Sand Castings, Large or Heavy Sand Castings

3 Types of Cores used in Sand Castings (Part 2)

Posted by Tim Carlstedt

      Back for more?! In the second of an installment about Core Knowledge, we will be discussing a few more common names and terms associated with Loose Pieces.  Loose pieces are used by Pattern Makers to create attributes that cannot be created normally without modification.  The types of loose pieces that we will discuss today are the Attached Pieces, Drawbacks, and Pick-Out Pieces. (P.S If you haven't read part 1 yet, then go check it out first)

Read More

Tags: Casting Design, Green Sand Casting Method, Casting Knowledge, Pattern/Foundry Tooling

3 Types of Cores Used to Make Sand Castings

Posted by Tim Carlstedt

How are hollow passage ways or special features put into a casting?


Through the Use of Cores that are Placed into the Mold Box!! 

In this part 1 of 2, we will discuss the common names and terms for Cores and Coreboxes that are used in the horizontal green sand casting method.  At CPM Industries, we often use Cylinder Cores, Balanced Cores and Dovetail Cores with Patterns to create the necessary passageways to meet the component's characteristics.  The article below discusses three types of cores that are placed on the parting line of the casting.

Read More

Tags: Ductile Iron Castings, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Sand Casting Design Improvements, CPM Industries, Green Sand Casting Method, Casting Knowledge, Pattern/Foundry Tooling

What is a Rapid Prototype Aluminum Casting?

Posted by Tim Carlstedt

What is the difference between a Rapid Prototype Aluminum Casting versus an Aluminum Hog-Out?  Also, why would you choose one over another?  Well let’s clarify what each is:

Read More

Tags: Aluminum Castings, Aluminum Sand Casting, Prototype Sand Castings, Aluminum Hog-Outs, Rapid Prototype Castings, Rapid Prototype Aluminum Castings

3 Thoughts on Gray Iron Castings

Posted by Tim Carlstedt

    Today, I wanted to share 3 important thoughts on Gray Iron Castings that could help in a number of situations.  These topics include: Gray Iron’s Shrinkage, Gray Iron Stress-Related Problems, and Different Uses of Gray Iron Castings.  Shrinkage and Stress consideration must be regarded by all engineers no matter the alloy, but I wanted to give insight on what makes Gray Iron so special!

Read More

Tags: Cast (Gray) Iron Castings, Cast Iron (Gray) Sand Casting

3 Ways of Combating Common Defects in Iron Castings

Posted by Tim Carlstedt

   Ever have issues of “Hot Spots”, Cracks, Tears, or Porosity in your Iron Castings?  Most of the issues will typically arise due to the design of the casting (click here for advice on designing Iron Sand Castings), however there are some things that a metal caster will consider before a project gets under way.  

Read More

Tags: Ductile Iron Castings, Sand Casting Design Improvements, Casting Wall Thickness, Quality Control of Sand Casting, Designing Sand Castings

Aluminum Sand Castings: Foundry vs. Finished Casting Supplier

Posted by Tim Carlstedt

  One determination that all Aluminum Sand Casting buyers must consider is whether their project is best suited to be manufactured at either an Aluminum Foundry or a Finished Aluminum Casting Supplier.  There are a lot of little aspects that go into this decision such as: Quantity, Delivery Time, Material, Machining Capabilities (if necessary), and (for obvious reasons) Quality.  So, let’s distinguish the difference between the two supplier options. 

Read More

Tags: Aluminum Castings, Aluminum Sand Casting, Green Sand Casting Method, Turn-Key Sand Cast Components, Aluminum Sand Castings

3 Tips to Reduce Machined Sand Casting Cost

Posted by Tim Carlstedt

We often get asked by engineers, "What can I do to REDUCE THE COST of MACHINING A SAND CASTING?" 

   So, I put together 3 QUICK CONSIDERATIONS FOR REDUCING MACHINING COSTS.  These are ideas that all engineers should keep in mind while designing their component.  This can save money in engineering/programming time, labor time (Fixturing & Set-Ups), and machining time.  While every design is different, therefore these are just some general ideas that may not always be applicable.  The below tips can be applied for Prototype Aluminum Castings, Ductile Iron Castings, Gray Iron Castings, and any other Machined Sand Castings that you can think of! 

Read More

Tags: Casting Design, Secondary Machining, Finished Sand Castings, Machined Sand Castings

Low Volume Sand Castings Coming Back to America

Posted by Tim Carlstedt

 In this month's issue of Modern Casting, there is a very interesting article regarding the "Total Cost Castings" and I wanted to shed some insight on the article.  This article is geared towards the upcoming shift from Chinese to American Manufacturers.  While reading the key points below, consider how the US Manufacturing capabilities have changed over the last 10 years, what quantites and methods will this work best for, and how this may affect what you do every day. 

Read More

Tags: Casting Knowledge, Prototype Sand Castings, Tips for Buying Sand Castings, Low Volume Castings

Benefits of Aluminum Sand Castings?

Posted by Tim Carlstedt

Ever wonder what makes Aluminum such a popular choice for sand castings?  While there are a ton of factors that go into that decision, here is a list of the 6 reasons why Aluminum is chosen for so many different applications.

    1. Low Density

      1. Weighs 1/3 of Steel
    2. Good Conductor of Electricity

    3. Non-Combustible  and Non-Magnetic

      1. These traits are excellent and make the alloy invaluable for projects that involve electronics
    4. Non-Toxic

    5. Malleable/Ductile

Read More

Tags: Aluminum Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Tips for Design Sand Castings

General Tips for Buying Sand Castings

Posted by Tim Carlstedt

So, You're Buying Castings.. Avoid the headaches by considering and implementing these 5 tips:

  1. Find a Firm that has Turn-Key Operations

    1. It is important to find a firm that can handle your project from start to finish.  This has a ton of implications that can save you time and money. 

  2. Avoid Finger Pointing

    1. Example: The day comes for your project build and castings finally arrived! Hooray! Months of designing and planning have all come to this. Everyone is excited to get this build started, but then you open the boxes and see the castings. Your worst nightmare comes true - the castings look awful and there are a ton of machining and other quality issues. OH NO! So you call the Machine Shop and they blame the foundry. Then the foundry tells you it's the Machine Shop's fault and the cycle of blame starts. As your head starts to throb you think to yourself, "Why didn't they stop machining if they saw issues with the castings?" Either way, now you have pay for expedition fees in order to get the castings done as soon as possible to get the project back in line. Where did it all go wrong?!?

    2. Since we handle all steps of the casting process (i.e. pattern, castings, machining, and testings) that leads to NO FINGER POINTING between different places. If, in the case something does go wrong, we take full responsibility for the casting.

  3. Do Less Paper Work!

    1. Spend most of your day doing Paper Work? Sending Multiple PO's and e-mails to Multiple Places/Contacts can be vary time consuming. The key to making your life easier is to work with a shop that can handle all aspects of the job and provide you a finished cast component on your doorstep.

  4. Find a Firm that has the Ability to Handle Different Alloys

    1. Have a project that calls for Ductile Iron 65-45-12 Casting and also an Aluminum 356 T6 Casting?  Cut down on all the e-mails by choosing a firm that provides multiple  finished casting on time and reduce your time (Remember - Your time is valuable) involved in planning, organizing, and tracking each peice of the puzzle. 

  5. Find a Firm That Offer Engineering Assistance

    1. Engineering Assistance can mean a lot of things, but it is important to find a firm that will help your engineering team with tips for designing your component so that it is more castable and easier to machine.  This will ultimately make the castings more economical and ergonomic.  Wouldn't that be nice?!

 

 

We hope these General Tips for Buying Sand Castings will provide you some insight on making your life simpler and more efficient!!

So, what can CPM do for you? Simply, we MAKE YOUR LIFE EASIER!

Our goal is to make your life easier through CPM's commitment to communication, quality, integration, and flexibility in order to provide efficient manufacturing of Prototype to Low Volume Sand Castings.  So let CPM show you what we can do by contacting us by clicking here.  Good Luck!

 New Call to action

Read More

Tags: CPM Industries, Ductile Iron Sand Castings, Aluminum Sand Castings, Finished Sand Castings, Tips for Buying Sand Castings, Turn-Key Operations

5 Tips for Designing Aluminum Sand Castings

Posted by Tim Carlstedt

We are often asked here at CPM Industries, "What are the Best Tips for Designing Aluminum Sand Castings?"

While we could go on for several pages while answering this question, so we have decided to offer 5 general Tips for Designing Aluminum Sand Castings.  These tips are to help you with both ease of manufacturing, improve your end products, and reduce costs per component.

Read More

Tags: Aluminum Sand Castings, Designing Sand Castings, Tips for Design Sand Castings

Sand Casting vs. Investment Casting

Posted by Tim Carlstedt

What are the advantages and disadvantages between the Green Sand Casting Method and the Investment Casting Method?

This is a common question for the metal casting industry and CPM wanted to shed some light on the subject.  In this entry, we will first look at a comparision of the two different methods, followed by a explanation of the table, then lastly another table highlighting the advantages and disadvantages of each method in comparison.

 

Comparison of Green Sand Casting vs. Investment Casting

 

Green Sand Casting Method

Investment Casting Method

Relative Cost in Quantity

Low

Highest

Relative Cost for Small Number

Lowest

Medium

Permissible Weight of Casting

Unlimited up to approx. 1 ton

Ozs to 100 lbs.

Thinnest Section Castable (Inches)

1/10

1/16

Typical Dimensional Tolerance (Inches)

.012

.01

Relative Surface Finish

Fair to Good

Very Good

Relative Mechanical Properties

Good

Fair

Relative Ease of Casting Complex Design

Fair to Good

Best

Relative Ease of Changing Design in Production

Best

Fair

Typical Base Tolerances

+/- .040 – 1.00 in

+/- .003 - .008 in

Typical Surface Finish

150 – 350 RMS

63 – 125 RMS

Minimum Wall Thickness

.140 - .250 in

.094 - .187 in

Typical Tooling Cost

$800 to $5,000

$3,000 to $10,000

Well, WHAT DOES THAT MEAN TO ME?!

Read More

Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Casting Knowledge, Secondary Machining, Finished Surfaces, Prototype Sand Castings, Pattern/Foundry Tooling, Patterns for Sand Castings, Cast Iron (Gray) Sand Casting, Investment Casting Method

Need a good laugh today? Here is how NOT

Posted by Tim Carlstedt

It's Friday, Need a good laugh today? Here is how NOT to use your equipment.. We found this video after attending the IMTS Show and viewing some incredible robotic arms.  If you did not get a chance to attend the IMTS (International Machine Technology Show) this year, then make sure you get down to McCormick's Place next time it is back in town!  Enjoy!!

Read More

Tags: CPM Industries

Ranking Machinability of Sand Castings

Posted by Tim Carlstedt

    Machining a Sand Casting is a major cost contributor in a project that involves a finished casting. The major factors to in determining Machinability are the alloy's hardness (meaning softer is better), how long the cutting tool will last, and time it takes (includes labor) to complete all the operations in machining. 

Read More

Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Secondary Machining, Cast Iron (Gray) Sand Casting

Subscribe via E-mail

Most Popular Posts

Follow Me