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Adaptor Plate
Introduction
Adaptor Plate: Problem
After complete assembly, the machine is punched for identification. Punching is done on the adaptor plate at a particular spot. Many times, punching was found very difficult, as hardness at the location was found excessive. This resulted in un-clear marking and also Necessitating more than one hammer-blow to the casting. Slippage while punching has also been a cause of injury to the operator.
Punching Location
Punching location is depicted by the arrow in the photo and the front view of the casting.
Limitations In problem-solving
For reducing hardness of the casting, chemistry could not be changed, as metal grade-specifications were fixed. Pouring-temperature could not be increased, as this would increase shrinkage-tendencies in the casting.
Reason of Earlier Faulty Gating As the casting is almost symmetrical, gating had been provided without considering the fact that punching is required at a particular spot and that the wrong gating could result in punching-difficulty.
Solution
Metal was introduced in to the mould cavity from a relatively nearby location. This would result in slower cooling of the particular spot of punching'. For pouring difficulty, location of the gating system on the match-plate was kept the same and the pattern was revolved on the plate, so as to suit the new metal- entry in to the mould-cavity
Principles Used
Continuous Cooling Diagram
Conclusion
All the castings poured after modification were acceptable. Thus, the theoretical application of basic metallurgical principles has helped solve the problem.