Low reject rates at the machine line typify permanent mold gray iron castings and result from high melt integrity. Eliminate Leakers Leaky castings are a messy and costly problem. With hydraulic and gas components, pressure testing is common after complete machining. Because permanent mold gray iron castings are essentially free of porosity, savings are realized through fewer rejects and even elimination of leak testing. Fast Cuts - Long Tool Life Machining time and tool life are common productivity measures.
Improvements depend on the relative quality of castings compared, and can vary from amounts shown.
First Cuts First cuts are most troublesome and costly in machining operations. In addition, variables are complex, difficult to define, and rarely quantified. No chilled corners or edges Minimal protrusions, swells, mismatch Machined Finish and Tight Fits Mirror-like finishes are possible on machined permanent mold gray iron castings because of the unique metallurgy. Ease of machining allows reduced clamping forces during machining. Distortion is reduced making it possible to obtain tighter tolerances in complex and thin wall components.