Wavertree Pillar PalmPresented By:

The University of Wisconsin PlattevilleSenior Design

The Design

Solidworks drawing of cast part after adding the parting line modifications to the bottom cylinder

The Design

Solidworks drawing of final product after all steps completed

Rivet Holes

Chamfer&

Step

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Pattern Design

• Mastercam drawing of pattern assembly

• Core (lower half), Pattern (upper half)

Core

Pattern

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Tool Path for Machining

Tool paths for final machining of part

Tool paths for machining cope half

of pattern

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Tool Path for Machining

Start of machining program for cope of pattern as shown in

Mastercam

End of machining program for cope of pattern as shown in

Mastercam

Solidification Modeling(MagmaSoft Program)

Video of Solidification in

MagmaSoft

Niyama criterion in MagmaSoft

Solidification Modeling(MagmaSoft Program)

Video of mold being filled using Magma

Machining Pattern

Machining program for location holes

as shown on the 2-axis CNC mill

Machining program ½ done for cope of pattern as shown on the 4-axis CNC

mill

Machining Pattern

Program near finished for cope of pattern on 4-axis

CNC mill

Cope of pattern finished on 4-axis

CNC mill

Machining Pillar Palm

Fixture for machining step on

bottom of part.

Fixture for machining step on bottom of part with

part on it.

Drilling Rivet Holes

Fixture for machining holes in

palm with part being machined

½” endmill milling holes after drilling

operation

Machining Chamfer and Step

Chamfer on bottom of part being

machined

Step on bottom of part being machined

Project Photos

Gating and Riser Design

Foseco Riser

Pillar Palms

Gating

Gating and Riser (Cross Section)

Pillar Palms

Foseco Riser

Gating

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Solidification Modeling(Solidcast Program)

Shows how casting solidifies after pour

A27 Steel Chemical Composition

• Required 5 test pours to obtain correct composition–5 test heats = 663 pounds of steel

• 14 Heats total = 1848 lbs melted• Composition

–Equivalent to Mild Steel• 0.192% Carbon (C)• 0.974% Manganese (Mn)• 0.794% Silicon (Si)

Personal Protective Equipment

• Hard hat with shield• Safety glasses• Aluminized jacket• Aluminized apron• Aluminized spats (cover legs and ankles)• Aluminized gloves • Steel toed shoes

PPE Required For Grinding

• Hard hat with shield• Ear plugs• Safety glasses• Flame resistant jacket

• Steel toed shoes

Coordinate Measurement Machine

• Inspected prototype• Made positioning fixture• Visited “Stainless Foundry and

Engineering” for consulting• Measured each

casting for tolerances

Coordinate Measurement Machine

• Centerline – center hole to center hole

• Distance betweenhole and centerline

• Degree of anglefrom center ofhole to centerline

Measurement Points

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Tensile Bar Testing• Made keel blocks• Machined tensile bars• Pulled tensile bars tests

–Tensile strength–Yield strength–Elongation

• Results–All parts met specification

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Donations Make the Difference

Cost: Purchased vs. Donated

71%

29%

Donated Purchased

Without donations this project would not be possible

Thank You to our Donating Companies

J. B. DeVENNE

Project Photos

Overhead Costs• Sand mixer and self centering vice• Increased mold making and machining efficiency

• Sand mixer - $30,000• Vice – complete donation

Overhead CostsItem Cost

Sand Mixer $ 8,000.00 Self Centering Vice $ 2,733.00

Grand Total $ 10,733.00

The Breakdown

Cost Per Unit (Sand Mixer, Labor, Vice included)Cost Totals

Donated $ 4,355.15

Purchased $ 1,755.81

Labor $ 68,600.00

Sand Mixer $ 8,000.00

Grand Total $ 82,710.96

Cost Per Part $ 2,067.77

All costs included

• No sand mixer, vice or labor included in total cost–Platteville students are free labor

The Breakdown

Cost Per Unit (No Labor Included)Cost Totals

Donated $ 4,355.15

Purchased $ 1,755.81

Grand Total $ 6,110.96

Cost Per Part $ 152.77

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Facts and Figures• Resources Consumed• 8000 pounds of sand• 1800 pounds of slitter scrap (steel)

• Over 2500 man hours• $1800 in purchased goods• $4400 donated by outside

firms

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Project Photos

Project Photos

Thank You• Dr. Kyle Metzloff Ph D.

–IS 4610 Professor• Ray Monroe

– Steel Founders Society (SFSA)• Philip Harrison

– Penumbra Design• Benji Johnson

–Magma Soft• Greg Gauerke

–Perfect Pattern – Core Box Build• Scott Sharpee

–Neenah Foundry

The University of Wisconsin Platteville

Thanks you for your support