One of the keys to our mutual success is to involve Benton Foundry in the design phase of the casting. We can offer input as to how you can improve castability, simplify machining and reduce total net cost. The earlier you get Benton's team involved, the smoother the prototype, sample and approval process will go in order to get the job into full production. CAD file reviews, 3D modeling and solidification analysis are just a few of the services we offer. Converting forgings and weldments to cast parts is also offered by Benton Foundry engineers, reducing your costs by 15% or more.
In a perfect world, the following information initially would be helpful in expediting your castings. Just as we have a responsibility in providing you good castings, you, the customer, also have a responsibility since they are your castings designed to your specifications. In the absence of information, we will refer to what we believe to be common industry standards.
- A model or drawing to the current revision level. In absence of the aforementioned, reverse engineering a casting may be an alternative.
- Casting number and/or part number along with where on the casting the part number, foundry ID and heat date should appear.
- Revision date and/or revision level.
- If the part is being revised, then a detailed notation specifying the exact change needed.
- Material the casting is to be made of.
- Heat treat specification, if any.
- Rough casting weight.
- Annual volume and anticipated order quantity.
- Areas to be machined and the amount of machine stock required.
- Datums and fixturing locations for machining.
- Desired parting line and draft angles.
- Tolerance of angles, radii and dimensions.
- Location on casting to verify hardness.
- Special notes and critical characteristics.
Once the design is approved by you, Benton Foundry can source the fabrication of pattern equipment with local pattern makers, who are at our facility on a weekly basis. This approach allows us to receive competitive bids on tooling that can best meet your needs in terms of dimensional accuracy, part intricacy, expected annual usages, availability and price. Patterns and coreboxes are produced using materials appropriate to meet your needs: Iron, aluminum, urethanes or wood (for prototypes). Patterns are produced utilizing both CNC machining processes and more traditional methods.
Testing and Inspection Requirements
An itemized list of testing and inspection requirements you require on samples and on production lots will also be needed. The following are available, however, as the requirements increase, so does the cost.
- Visual Inspection
- Hardness, with or without a histogram
- Dimensional Layout
- Chemical Certification
- Physical Certification
- Metallographic Analysis
- Letter of Compliance
- Control Plans
- Capability Studies
- Part Retention
- Liquid Penetrant Testing
- Bore Scope
Finite Solutions Solidification Analysis