Vacuum assissted Lost Foam casting Compare with Green Sand Molding (considered 300 ton/month foundry)

110 kg Casting
v-LFC System Casting per Flask ( 1 flask * 2 pcs) 2 Green System (1 mould *1pcs )
Molten Metal per flask kg 258.8 Unit Value
Sand wasted after reclaimer + core
Average Yield Target % 85% Sand wasted after recycle kg 1% 17.76 Sand
Dry Sand Price taken Rs/kg 2.50 Cost of wasted sand
LFC Tree configuration Cost of Molding sand 44.41 Sand needed for Mold
110 kg Casting Nos 2 EPS Foam required per flask kg 0.86 Sand Needed for Core
Weight of each casting kg 110.0 EPS Waste in moulding kg 0.04 Core Sand Cost (breakage accounted)
Moulding Sand Cost/mould (reclaiming
Net casting Weight per tree kg 220.0 EPS price Rs/kg 125 included)
LM needed kg 258.8 Cost of Foam Pattern 113 Core cost / box
Flask Size LFC Paint required kg 10.4 Sand Mould material Cost
Length m 1 Paint Price (powder to liquid) Rs/kg 42 Paint Mould & Core
Breadth m 1 Paint Cost (10% waste added) Rs 435 Moulding Labour
Height m 1.2 Energy cost+ Heating +Steam etc Rs 246 Total Moulding Cost
Inside Volume m3 1.20 Misc Expenses Glue, Bamboo Sticks etc 15 Cost per kg for moulding
Volume of Metal Poured m3 0.03
Sand volume per flask m 3
1.17 Moulding Manpower (300t/m) Rs/kg 316.8 Knockout/Fettling/Grinding etc
Weight of sand per flask kg 1776 Total Moulding Cost + Ingate cutting & grinding 1170 Foundry Cost per kg without metal
Cost per kg for moulding +Other Expenses 5.32
Flask Size Green Sand Molten Metal needed
Length m 1 Molten Metal needed kg 85% 259 Assumed Molten metal Price
Breadth m 0.8 Assumed Molten metal Price Rs/kg 38 Metal cost
Height m 0.70 Metal cost Rs 9835 Return
Inside Volume m3 0.56 Return Rs 20 776 Casting cost
Volume of Metal Poured m3 0.019 Casting cost Rs/kg 46.50 Note:
Sand volume per flask m 3
0.54 Note: Foundry Rejections due to core/mold shift
Weight of sand per flask kg 823 General Foundry Rejections (actuals) 1.0% 3 & Blow holes in kg (Claimed)
Net 49

General Dynamic Multi Technical Consultancy LLP

steel@gdmtechnics.com
 Workforce needed in LFC Molding & Fettling Per piece Cost as cast after fettling 5399
Station Worker Supervisor Savings per piece 2179
Boiler 1 Delivery to next stage within 1 days of pouring Your Data
Pre-Expander 1 NO rejection due to Moisture & Gases As-Cast Weight of Casting - 110 Kg

Molding m/cs 3 3 1 Savings in Machining cost (1 to 2.5 mm max at tool point) Bunch weight - 152 Kg

Assembly 6 All holes above 15% will be As-cast Present Sand system with Sand Metal ratio Green

Coating 2 1 Foam Molds can be stored for even 3-5 months Core Weight and number of cores, -- Total Core wei

Mold closing 3 Core sand sytem - Cold Box Process

Savings of minimum 8 % weight, you only get benefit if sold
Fettling 2 1 per piece but customer gets benefit anyway Metallurgy and Yield achievable at present. Fg 26

Total 17 3 Foundry Savings 29%

Per Shift 20 say with relivers + Savings in Machining
2 Shifts 8 hrs 40 43 Big Savings in Rejections
+ Savings in Salvaging cost

General Dynamic Multi Technical Consultancy LLP

steel@gdmtechnics.com
0 ton/month foundry)

m (1 mould *1pcs ) 1
Unit Value
d after reclaimer + core
kg 3% 106.30
ed sand 265.75
d for Mold kg 823
d for Core kg 95.0
ost (breakage accounted) Rs/kg 5.50
and Cost/mould (reclaiming
Rs 0.5 411.55
Rs 522.50
material Cost Rs 1199.81
Rs 10.00
Rs 242.0
1452
for moulding 13.20

ettling/Grinding etc Rs 2
st per kg without metal 15.2

kg 73% 150.7
olten metal Price Rs/kg 38
Rs 5726
Rs 20 814
Rs/kg 59.86

ections due to core/mold shifting/Pin 6% 9

s in kg (Claimed) Net 69
7579

General Dynamic Multi Technical Consultancy LLP

steel@gdmtechnics.com
 Your Data
t of Casting - 110 Kg

- 152 Kg

ystem with Sand Metal ratio Green sand Process , 1:10

nd number of cores, -- Total Core weight - 95 Kg , 5 no cores

m - Cold Box Process

Yield achievable at present. Fg 260 Grade

General Dynamic Multi Technical Consultancy LLP

steel@gdmtechnics.com