CIREX has the knowledge needed to develop product-specific alignment and calibration templates. This allows the casting to be aligned with great precision so that no finishing is required. Alignment and calibration are understood to mean: intentionally having the steel product (casting) adopt a different direction or form. The use of an alignment jig is necessary for this. The steel product is placed in an alignment jig and this is closed with a hydraulic press. By placing the product under a pressure load, plastic deformation occurs and the product adopts the shape defined by the alignment jig.
DIFFERENT ACCESSORY TOOLS
Just as the word suggests, an adhesion template is used to ‘glue’ a wax model to a branch. Whenever a wax model is injected using a single series matrix, this must then be “treed up”. This is done by placing the products in an adhesion template. The product is then joined to the branch with a hot soldering iron. This means that all products are glued on to the tree in the same way and with a constant intermediate distance. This ensures a uniform method of adhesion and stable product quality.
If wax models are injected into a multiple series matrix, an adhesion template is unnecessary: the branch with the associated wax models is injected in a single injection simultaneously. The branch is made with a single injection and can be completely treed up after cooling down.
After the steel products have been cast, the ceramic layer is removed and the products are vibrated or sawed off the steel trees. After the product has been sawn off, a larger “remnant” gate remains attached to the product. With a chopping jig, this cut can be removed as precisely as possible. The product is clamped into the chopping jig, and the gate is then sawn off as precisely as possible. By using a chopping jig, the product is always set up and sawn off in exactly the same way. The functional portion of the product cannot be damaged and all the products are equivalent. This also keeps the products from being sawn through by accident or from having various lengths of remnant gate remaining attached to the product.
However, it is not always necessary to use a chopping jig. If the geometry (design) of the product permits, the product can sometimes be sawn off in a single go without a larger “remnant” gate remaining attached to the product. The remaining small “remnant” gate on the product then only needs to be sanded off. Chopping can then be skipped, which results in a cost advantage.
After the product has been sawn or vibrated off, a small “remnant” gate remains attached to the product. This remainder can be sanded off using a sanding jig. This helps remove the gate from the product with great precision so that it no longer can be found on the product. As with the chopping jig, the product is always sanded in the same manner, so that every product is identical. By working with a sanding jig, you are guaranteed high precision and constant product quality.
This also keeps products from being sanded improperly by accident. However, not every product requires a sanding jig. There are also products that are sanded by hand because the design and/or the form of the casting do not permit the use of a sanding jig.
Alignment is not necessary for all cast products. Alignment is limited to those products that adopt an undesired shape during the coagulation process (cooling off). This cannot always be prevented as it is part of the casting process.
The need to align is mainly related to the geometry (design) of the product and the chosen steel alloy. These have a huge influence on the degree to which products can display deviations in shape during the cooling process. A part of the product can warp, parallel walls sometimes deflect, holes may become less round, etc. The overall cooling process can result in deviations in both shape and dimensions. Fortunately, these shape and dimensional deviations are marginal and not visible to the naked eye. They can, however, be made visible with good measuring equipment.
Your products are aligned to correct these tiny deviations in shape or dimension. They are placed under pressure and aligned to the shape that has been predefined. The big advantage of this is that no unnecessary and expensive post-processing needs be conducted to get the product back into the desired shape. With this approach, high-quality products in terms of both dimensions and shape can be obtained simply and cheaply.
CIREX develops the required alignment jigs itself since considerable knowledge is necessary for this. From our years of experience, our engineers know exactly how to design an alignment jig. When doing so, they take the product’s geometry into account, along with the size of any possible deviation, and the elasticity of the selected steel alloy. To a great degree, these determine the force required for alignment.
After the products have been sawn off, sanded and blasted, they are inspected for their functionality and dimensions. Products are placed in an inspection template to make sure that they fit during assembly. Using an inspection template makes it impossible for products to be delivered that do not comply with the specifications for dimensions and functionality. With this approach it is not necessary to measure all the products separately on a measuring machine. Proper dimensioning of the precision castings produced by CIREX is nonetheless safeguarded.
An inspection template need not be developed for every product. The requirement depends on the functionality, geometry and dimensions. These are the specifications that define the function of the component.
After casting steel components, additional bench work processing may be necessary. This may be milling or routing, or drilling and tapping threaded holes. In order to perform a process well, a clamping jig is developed and produced for each product. The clamping jig is product-specific and guarantees a stable finishing process.
As the name suggest, a clamping jig is a tool to clamp the products securely and then to process them mechanically in a lathe, router or drilling machine. Clamping jigs can be operated mechanically, hydraulically, electronically or pneumatically. Clamping jigs can also contain various sensors. These sensors recognise and monitor products and tools. If an error occurs in the processing cycle, the machine is stopped automatically. CIREX develops these jigs itself. Production takes place at a specialised toolmaker. A product specific clamping jig is made on the basis of the geometry, complexity and expected quantity of the products and the processing machine.