Mejoras del proceso de fundición mediante rediseño de moldes y horno de fundición

Abstract

This project is directed at a company dedicated to manufacturing irrigation accessories through aluminum casting, machining, and welding processes. The general objective focuses on redesigning molds to improve production efficiency, product quality, and the reduction of manufacturing costs; additionally, on structurally improving the furnace in order to ensure greater process and product safety. The hypothesis proposed a monolithic system focused on molds for higher-productivity components (6-inch valve coupling), for which a post-molding analysis of the current process was conducted; subsequently, technical and thermal criteria were applied in order to facilitate the implementation of basic, non-specialized machining. Furthermore, based on a thermal-structural evaluation of the existing furnace, a multilayer insulation system, a functional lid, and a pouring temperature control using a Type-K thermocouple were defined, with the purpose of eliminating dependence on the operator’s empirical visual criterion for determining the pouring temperature. Finally, a 70% increase in production is evidenced through the implementation of monolithic components, together with a cost saving of 28.33% (USD 11.33), an improved efficiency of 85% compared to 15% for the existing furnace, and an estimated fuel consumption saving of USD 50 per month. Keywords: modernization, LPG furnace, efficiency, mold redesign, overheathing savings, operator dependence