Yasemin Nur Aydın, Onur Özaydın, Alper Akış

Static Analysis of the Slotted Upper Plate of Low Pressure Casting Machine

In this study, the process improvement / Kaizen case study of a casting mold set-up process, was examined.The aim of this work was reducing the set-up time and improving ergonomic conditions. Since existingoperating conditions cause a waste of time, an air impact wrench had to be used in the mold assemblyprocess. To be able to use the air impact wrench, a new geometry had to implemented on casting mold andthis design change was analyzed in ANSYS software to avoid a failure in working conditions. It wasconcluded that the maximum stress on the mold was not at a level where it would cause failure. After theinitial geometry improvement process, a further ANSYS-Topology optimization process was conducted toreduce weight of the mold. As a result, the set-up time decreased. Consequently, big benefits in terms ofcycle time, occupational health and safety, improvement in the process and cost have been achieved.

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