✅ Change the Casting Process to Eliminate Grinding and Reduce Finishing Costs
🔹 Introduction
In many foundries, post-casting finishing processes such as grinding and surface treatment are considered essential. However, these steps significantly increase overall production costs, extend lead times, and increase reliance on labor and equipment.
In this project, by redesigning and optimizing the casting process, we successfully minimized the need for post-casting grinding. Without disclosing the specific method used, the improvements were achieved through deep analysis, intelligent tooling redesign, and refined process control — all aimed at producing near-net-shape castings with superior surface quality.
🔹 Initial Assessment and Problem Identification
A comprehensive evaluation of the casting quality was carried out, focusing on:
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Surface defects such as roughness, scoring, and flash
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Dimensional inaccuracies and distortion
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Solidification pattern and thermal gradients
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Flow behavior of molten metal and critical mold areas
The analysis revealed that a significant portion of grinding requirements stemmed from turbulent flow, poor solidification control, and inefficiencies in gating and venting systems.
🔹 Corrective Measures
Based on the insights gained, the following improvements were implemented:
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Redesigned gating system to reduce turbulence and control solidification
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Mold geometry optimization and improved venting for smoother surfaces
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More accurate control of melt chemistry and pouring temperature
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Optimized mold filling sequence based on simulation results
🔹 Achievements
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✅ 70% reduction in post-casting grinding operations
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✅ 30% decrease in finishing department costs
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✅ Stable surface quality meeting international standards
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✅ Reduced abrasive tool wear and extended mold life
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✅ Improved process repeatability and product consistency
🔹 Conclusion
Through targeted changes to the casting process, significant savings in finishing time and costs were achieved — without the need for additional process steps. This success demonstrates how expert analysis and technical adjustments in foundry operations can lead to better quality and higher efficiency.
If your foundry is facing high costs due to extensive grinding or surface finishing operations, our team at Tahlilgaran Zob is ready to deliver specialized, cost-effective solutions tailored to your process.
