Nearly 30 years ago I was involved with producing tooling to cast the aluminum block for the (Cosworth) Ford 4.6 L used in the Lincoln Mk VIII. The tooling used many of these techniques. There were others too. We maintained a 0.007 (inch :) ) tolerance, and 4.5 mm wall thickness. The block contains some "novel" geometry around the end of the integrated water-pump housing :). The "valley", where the two flows come together, used a crisscross patter to hold back the top of the flow where the metal may have cooled and/or contain bubbles, so the hotter/purer metal can flow together, mix, and join better. The pattern was made using a large chunk of carbon and EDM. So many things were passed on to me from these pattern makers. Many of them are gone now. The pattern shop (Wisconsin Pattern, Racine WI) is gone. At the time there was a strong push by the shop, union, and Ford to bring work back to the 'states (as it were) and inject it with new technologies. The shop sponsored my venture into contract consulting, encouraging me to leave the large CAD/CAM/CAE software company Ford standardized on at the time. I provided customized software, and indepth support regarding the CAD/CAM products. But, as I told them, I learned far more from them than they learned from me. Still, they (including the union) seemed more than happy teaching and informing me, including sessions in the wood shop and time on manual and CNC machines, and producing 100's of production tool paths and continual face to face interaction with machinists. All helped me to refine the tool paths I produced. I stayed on to win the production tooling contract for this block. Then for 3 more prototypes and a production set of boxes (Triton 4.6, 5.4, and 6.8 L, 2-V8's and a V10) for Ford's Next Generation Truck (i.e. NGT's) engines. Heady times. Manufacturing gets into one's blood and it never leaves.
Wow, what an explanation - great teacher. I think this is a must watch for any hobby caster looking to start getting a little more serious on the subject.
David, you can purchase ceramic foam filters from Canfield & Joseph, Del Sol Services, or Porter Warner. Brands are Selee, Foseco, and other Off Shore variants.
He made the top of the bag a funnel shape while blowing into it. The point is that the air he was blowing was drawing in even more air that from his lungs.
Great lecture but really really stupid cameraman and editor. What’s the point of showing a screen we can not even seen what’s on it? Beyond stupid and total waste of time for what otherwise would have been a great lecture.
@@muslimmukhtarkhanov8194 Потому что воздух в стальном фасонном литье (тяжелее, грубо, 15 кг.), который увлекается потоком расплава и приводит к браку - это миф. Они отлили годное, потому что фильтры поймали неметаллические включения типа шлака, футеровки и пр., вероятно. Потом, сифонная заливка может и вредить.
@@kosee4008 Константин, мне кажется вы хороший знаток литейного дела. Можно ли вам написать на эл почту и посоветоваться кратко по некоторым вопросам. Дело в том, что я с недавних пор увлекся литьем с применением 3д принтера (для печати форм- выплавляемые модели) и мне нужно посоветоваться с экспертами, если можно так выразится, этого дела
I found this immensely informative and very useful. all of the phenomena discussed was practicable at home as much as at the industrial level. Very very easy to design a few gates and other patterns to create the environment described. The only part that might be more difficult is adding the filters, but as mentioned above, these filters are available to buy.
Nearly 30 years ago I was involved with producing tooling to cast the aluminum block for the (Cosworth) Ford 4.6 L used in the Lincoln Mk VIII. The tooling used many of these techniques. There were others too.
We maintained a 0.007 (inch :) ) tolerance, and 4.5 mm wall thickness. The block contains some "novel" geometry around the end of the integrated water-pump housing :).
The "valley", where the two flows come together, used a crisscross patter to hold back the top of the flow where the metal may have cooled and/or contain bubbles, so the hotter/purer metal can flow together, mix, and join better. The pattern was made using a large chunk of carbon and EDM.
So many things were passed on to me from these pattern makers. Many of them are gone now. The pattern shop (Wisconsin Pattern, Racine WI) is gone. At the time there was a strong push by the shop, union, and Ford to bring work back to the 'states (as it were) and inject it with new technologies.
The shop sponsored my venture into contract consulting, encouraging me to leave the large CAD/CAM/CAE software company Ford standardized on at the time. I provided customized software, and indepth support regarding the CAD/CAM products. But, as I told them, I learned far more from them than they learned from me. Still, they (including the union) seemed more than happy teaching and informing me, including sessions in the wood shop and time on manual and CNC machines, and producing 100's of production tool paths and continual face to face interaction with machinists. All helped me to refine the tool paths I produced.
I stayed on to win the production tooling contract for this block. Then for 3 more prototypes and a production set of boxes (Triton 4.6, 5.4, and 6.8 L, 2-V8's and a V10) for Ford's Next Generation Truck (i.e. NGT's) engines. Heady times. Manufacturing gets into one's blood and it never leaves.
Wow, what an explanation - great teacher. I think this is a must watch for any hobby caster looking to start getting a little more serious on the subject.
Simple explanations, like Richard Feynman explaining how the space shuttle blew up. So smart that he can explain it to the normies.
4:00 - What a Gem of knowledge. Thank you for this!
somebody get that guy in the audience a glass of water jesus christ
Report him to the CDC
Really annoying 😡
Awesome explanation! I have a feeling I'm going to love casting even more in the near future!
such fantastic, and once you know, fantastically obvious information. great work!
thanks for putting this up,
I watched this entire thing. I don't even own a foundry.
Well, I know what I'll be trying on my next casting! 😊
شكراً لك يا دكتور
What are those "tangential filter gates", how can I get them or install them on my molds?
Where can an individual purchase these filters in the US?
Also, where can I learn more about these methods?
David, you can purchase ceramic foam filters from Canfield & Joseph, Del Sol Services, or Porter Warner.
Brands are Selee, Foseco, and other Off Shore variants.
what about high production foundry like on a hunter 10 automated moulding machine how would you work that
I wonder if the Indian manufacturers are aware of these detals.
14:10 conical basin “simulation”, how did he do it? Can’t see it clearly
He made the top of the bag a funnel shape while blowing into it. The point is that the air he was blowing was drawing in even more air that from his lungs.
Great video. I'm in Canada I would like to speak to Bob "cough cough" could I get more details on him. at 15:40 in video
Samuel, did you ever get in touch with Bob and find out where he does his casting? Thanks.
I’ve never heard more people coughing & hacking during class in my life… geez get it together people, that’s disrespectful….
Covid in the stands
Eh! Canada casting are the best in the world hmmm!
That one always coughing 😡😡😡
Great lecture but really really stupid cameraman and editor. What’s the point of showing a screen we can not even seen what’s on it? Beyond stupid and total waste of time for what otherwise would have been a great lecture.
Can't see or hear shit
Nothing usefull, unfortunately...
почему?
@@muslimmukhtarkhanov8194 Потому что воздух в стальном фасонном литье (тяжелее, грубо, 15 кг.), который увлекается потоком расплава и приводит к браку - это миф. Они отлили годное, потому что фильтры поймали неметаллические включения типа шлака, футеровки и пр., вероятно. Потом, сифонная заливка может и вредить.
@@kosee4008 Константин, мне кажется вы хороший знаток литейного дела. Можно ли вам написать на эл почту и посоветоваться кратко по некоторым вопросам. Дело в том, что я с недавних пор увлекся литьем с применением 3д принтера (для печати форм- выплавляемые модели) и мне нужно посоветоваться с экспертами, если можно так выразится, этого дела
I found this immensely informative and very useful. all of the phenomena discussed was practicable at home as much as at the industrial level. Very very easy to design a few gates and other patterns to create the environment described. The only part that might be more difficult is adding the filters, but as mentioned above, these filters are available to buy.
@@Lambrequin Do you know from what Mr. Campbell decided that air is a problem? Please, read the book. It is not correct answer from his side...