Development and implementation of an integrated technology for the mechanical processing of thin-walled cast iron castings with complex shapes and extensive surfaces, supported by advanced quality control techniques.

Project

Development and implementation of an integrated technology for the mechanical processing of thin-walled cast iron castings with complex shapes and extensive surfaces, supported by advanced quality control techniques.

Project objective

Development of a process innovation in a form of machining technology for thin-walled iron castings of complex shape and developed surface, supported by advanced quality control techniques.

Project
value

PLN 13,262,386.88

EU funding
support

PLN 6,096,009.76

Project objective

As part of the project, a unique pilot line will be developed, which includes:

1. The process of final quality control of raw castings conducted using the NDT-RAM (“Non-Destructive Tests – Resonant Acoustic Method”) to automatically detect internal and surface defects and assess the quality of the spheroidising process.

2. The process of qualifying raw castings for the machining stage, during which the device developed as part of the Project will enable the automatic identification of internal defects such as cracks, voids, sand inclusions, porosity, and discontinuities. These defects were previously only discovered during the machining process carried out at the client’s facility.

3. The process of castings machining, during which compliant parts free from internal defects will be automatically picked up and placed in the working area of the CNC machining cell, and then processed using:

tool wear evaluation and forecasting systems,
machining stability monitoring solutions,
energy consumption measurement devices,
innovative, patented tools equipped with vibration-damping systems,
an eco-friendly cooling system.

4. The process of recovering waste material in the form of chips generated as a by-product of mechanical machining are cleaned, pressed, and re-melted.

5. Final quality inspection involves identifying the shape and dimensions of machined parts using 3D scanning technology.

Project results

The implementation of process innovation into Odlewnia Kutno’s operations will yield the following results, positively impacting the production process for grey and ductile iron components through casting and mechanical machining:
1. Vibration reduction.
2. Increased tool longevity.
3. Improved process stability.
4. Reduced energy consumption.
5. Enhanced surface geometry quality of machined parts.

This will directly result in:
1. The elimination of the risk of sending defective castings for external machining operations.
2. A reduction in complaints costs.
3. A decrease in the ongoing production costs associated with manufacturing defective castings.
4. An increase in re-use of production waste.

Learn more about the project

Source of financing