Category: Blog

3D scanning has revolutionized many industries. It has made an impact on almost all industries, from automotive manufacturers to mining. Structured light scanners work accurately and quickly. 3D scanners will scan an object multiple times and from different angles to produce a virtual design within seconds. These are a few reasons to use 3D scanning in manufacturing.

Faster Prototype Process

Putting together an accurate prototype will often require multiple attempts. With 3D structured scanning, you’ll be able to shorten this process. You may even reduce the number of prototype cycles needed during the production and design processes. A scan allows you to save data related to the scan, measure cross-sections, and identify areas that need help. Then, when you have to scan a new prototype, comparing the two will be easy.

Save Time in Design Stage

Imagine you need to create a new part based on a pre-existing design. Reverse engineering is simpler, and you can easily conquer this task with structured light 3D scanning. The scanner can provide precise measurements of where the new piece must fit because it can see into every nook and cranny.

The scanners also save time when you need to alter a current piece. A scanner can work faster and be more accurate than hand-drawn dimensions.

Able To Remanufacture Parts Without CAD

CAD, or computer-aided design, hasn’t always been around, so sometimes you have to remanufacture a part that originated before CAD was around. 3D scanning makes this process possible. You have to scan the old piece and use the reverse engineer software to design a CAD model. You’ll then use the scanner to compare the two and check for accuracy.

Compare Projects To Constructed Products

Another reason to use 3D scanning in manufacturing is to compare as-designed projects with the end product, guaranteeing that the original design was successful. Comparing plans is more than quality control; rather, it ensures that the produced product will fit as needed.

Cast Steel Products offer 3D scanning and reverse engineering, along with other products and services. We are a mill liner manufacturerthat presents quality designs optimized for each unique application. Visit our website today!

When discussing casting processes, two particular techniques come to mind: centrifugal casting and investment casting. Both methods involve pouring metal into a ceramic mold or die, but they have different techniques. These are the differences between investment and centrifugal casting.

Investment Casting

Investment casting is the process of creating a wax mold of a specific part. The design then becomes covered with molten clay that hardens into a shell shape. The wax is then burned or melted as the shape is filled with molten metal and cools down to form the part. You remove the mold to reveal the piece. The clay shell is only used once.

The investment casting process is best for complex and simple parts. Investment casting is used for high or low-volume production runs. This method is excellent for various metals, and you’ll find it used in multiple industries. These industries include energy, aerospace, medical, automotive, and industrial equipment.

Centrifugal Casting

This casting process takes molten metal, pours it into a die, then spins the entire cast. This force equally distributes the molten metal throughout the whole mold. You may use the die for the next piece you’re creating as well. There are two forms of processes: vertical centrifugal casting and horizontal centrifugal casting.

If you can’t use a specific process on a particular material, centrifugal casting is what you’ll use. This method is ideal for particularly large-sized parts. You can create pieces that are upwards of 135,000 pounds. It’s also best when the piece is symmetrical and rotated on its axis.

The Differences

Now that we understand each method a little, let’s look at how centrifugal and investment casting are different. If you have parts that have intrinsic shapes and details, investment casting will be your best method. If you’re forming a part with thin walls or tight tolerances, you’ll want to use investment casting. Investment is also your method if you’re looking to create small to medium prototypes. Centrifugal casting will be the appropriate choice if you need parts with large widths over 15 feet, castings formed from metals that can’t work with any other process, or any large casting.

Cast Steel Products is your go-to destination for all your heavy steel manufacturing products. Visit our website today!

There are several different casting processes to choose from; knowing which method to choose for the equipment you need can be difficult. So, how do you know which technique is best? The answer relies on the specifications of your product.

Explore how to choose the right metal-casting process and find the best method for your company.

What Is Casting?

Casting is a manufacturing method that consists of pouring a liquid—usually metal—into a mold to create a product. Many industries use casting, especially the mining and milling industries. They use metal casting to produce mill liners and other equipment.

Design

Different casting processes are chosen based on the design of the final product. For example, if you need a complex component, investment casting can be a good choice, especially for minute details. However, there are other casting options. Take a look at them below.

Centrifugal

Centrifugal casting rotates the mold at high speeds, which forces the liquid metal against the walls.

Die

In die casting, the liquid material is injected into the mold under intense pressure.

Investment

Investment casting involves a disposable ceramic mold. A wax pattern shapes the mold, and this allows for intricate detail or extreme accuracy.

Sand

Sand casting is a common method that uses sand as a mold. The sand mold is destroyed in the process, but the result is textured.

Choosing a Foundry

Knowing how to choose the right metal casting process also relies on finding a foundry that can help you find the best method for your product. Developing a relationship with a foundry if you need castings regularly can be advantageous to ensure they meet your needs while producing quality products.

Research foundries before settling on one. Tour the facilities and ask them how they ensure quality control and how comprehensive their capabilities are.

If you’re searching for a heavy steel casting manufacturer, contact Cast Steel Products to learn how we can foster a dependable partnership!

Did you know that mill liners impact the performance of an entire mill? Finding the right liner design for ball mills will help production immensely. Choosing the correct mill liner will provide lower maintenance costs, decreased downtime, and better outputs.

Explore the different types of mill liners you should know to find the right liner for your application.

Grid Liners

All ball mill liners must be very resistant and capable of withstanding high impacts. The milling process uses steel balls to break down the material. The grid liner has the dual role of protecting the cylinder while making the movement of the steel balls effective.

Double Wave Liners

People also use double wave liners for ball mills. These liners are prolific, but they need precise angles to fit into mills properly. Modifications typically occur since it’s hard to get the fit right the first time.

Solid Liners

Solid liners contain fewer pieces and are easy to install. But they have a higher scrap weight, and after they experience significant wear and tear, their performance quickly drops off.

Crusher Liners

When you’re selecting a crusher liner, you’ll need to consider the size of the feed going into the crusher. If it’s too small, the bottom portion of the crusher liner will wear out faster since the crushers are coned shaped. And if the rocks are too big, they will circulate at the top. You’ll have to study the feed size and determine if you need a liner to accommodate a smaller or larger feed.

There are vital factors to consider when selecting a mill liner. By understanding all the different types of mill liners you should know, you can determine which liner is best for your manufacturing needs. You can find crusher liners at Cast Steel Products. Browse our blogs to learn more about equipment for mining and manufacturing.

Did you know that grinding is a vital aspect of mining? Extracted material requires milling for it to be useable as a product. In mining, essential equipment is needed to break down minerals into granules. Everything from valuable metals like gold, precious gemstones, and minerals needed for construction goes through the milling process after being pulled from the ground.

Learn more about the importance of industrial grinding equipment in mining!

How Grinding Equipment Works

After mining for material, milling, or grinding, the next step is to make the material into a useable product. Even though industrial grinding equipment has only one purpose—to grind the material into small pieces—a mill can choose from several mill equipment options.

Ball Mills

The most common milling machine is the ball mill. It is a slightly inclined machine filled with balls, typically made from stone or metal. Workers add the extracted material to the ball mill, which grinds material into smaller pieces with friction from all the moving balls.

Autogenous Mills

Autogenous mills also rotate, except the milling of the material comes from the material itself. The rotation of the mill throws the material against the sides of the mill, causing it to break.

Pebble Mill

Sometimes, a product cannot be contaminated from the iron of the steel balls. In this instance, a pebble mill steps in; rock pebbles, either quartz or silica, provide a friction source along with ore particles.

High-Pressure Grinding Rolls

For mills wanting to replace ball mills, high-pressure grinding rolls are often the answer. They can achieve the same results but with much lower energy usage. Instead of rotating, two equal-sized rollers roll against one another, and a belt feeds the material into the rollers.

Once the material passes through the rollers, the extreme pressure creates fine particles similar to a ball mill.

Overall, the importance of industrial grinding equipment in mining is vital. The milling process turns raw material into the building blocks of everything around us.

Learn more by exploring the blogs at Cast Steel Products!

Finding the right metal casting supplier isn’t the same as searching for a supplier for hardware or office supplies. Metal castings are not a commodity; they are a specific application that requires precise measurements.

Not every casting supplier will meet your needs; they might meet the purchase requirements, but that doesn’t necessarily mean they can deliver the quality you need. Knowing what to look for when hiring a new metal casting supplier will save time and money.

Check out these considerations to make the process easier.

Market Experience

Don’t just go with the first casting supplier you find; do your research and make sure the foundry has experience in your market. Trusting a metal supplier that already understands the terminology, applications, and even the pain points of your industry will ensure they can anticipate any potential problems.

Luckily, most casting suppliers offer this information on their websites, making research even more straightforward.

Multiple Processes

Find a supplier that performs several different types of casting processes. Choosing a foundry that only has one method means they will try to sell you the benefits of that process instead of determining which casting is better for your product.

Machining Capabilities

Do you need machining capabilities? Metal suppliers with in-house machining can resolve a problem faster than if a third party does machining. Plus, there is less turnaround time since there won’t be shipping and handling by an independent machinist.

Added Value

Understanding what to look for when hiring a new metal casting supplier also involves considering what you need most from a supplier. What added values does your business need? Some considerations can include:

• Do you need a supplier to follow specs, then drop off the finished product?
• Are you looking for expertise in how to optimize your products with different materials?
• Would you like a supplier to review your designs and offer casting recommendations to lower costs or make your products longer lasting?

Some casting suppliers can be excellent at following your designs, but that’s it—and that might be what you need. Find out what your business needs before beginning your search for a new metal casting supplier. Doing so can result in a partnership that will last for years.

Need more information on industrial wear parts? Check out the blogs at Cast Steel Products!

A supplier is a person or company you trust; many years of trust will lead to a strong relationship. Let’s explore what to consider when hiring a mill liner supplier. It’s the single best thing you can do for your mill that will affect your entire operation.

Transitioning From OEM Liners

OEM liners, or original equipment manufacturer liners, are required for the first few years due to performance warranties. The liners are conventionally made to lower the risk of damage in the case of disruptions in the feed to the mill and electrical trips. Eventually, you’ll need to upgrade your liners to optimize operations.

Your Wear Life Requirements

Do you have any requirements for the wear life of your mill liners? Just because one supplier’s liners last longer does not mean that they are the best fit for your mill. Plan how your liner’s life will fit into the overall maintenance planning and functions. Once this is established, begin trials to determine the wear life of all competing products and how they measure up to your maintenance schedule.

What Their Optimization Plan Is

You want to look for mill liner manufacturers who have proved that they have knowledge and experience optimizing liner designs. The best suppliers will demonstrate their expertise and understanding with an eagerness to innovate their design capabilities. Cast Steel Products works closely with you to provide optimization and expertise.

How Cost-Effective They Are

Mechanical design skills must be at the top of your list. Fitting problems in relining will extend closures and lead to significant production deficits. Even though internal shell dimensions and liner bolt drilling drawings are made available to you, it’s also wise to verify the details with site measurements. You should cast the dimensions using 3D scanning technology if deformation or wear has altered the size.

You must be able to recognize all aspects of your liner’s design and purpose. Choose a supplier that will provide the appropriate elements in their product. These elements include mechanical design, modern simulation tools, advanced materials technology, and a deep understanding of your process. We hope this article has provided better insight into what to consider when hiring a mill liner supplier.

Neglected tools can lead to unnecessary wear and tear that can reduce productivity at the job site. But you can easily prevent expensive damage to your machinery by scheduling regular maintenance that will improve efficiency, specifically in the form of a higher digging and grading performance with maintained ground engaging tools.

Ground engaging equipment is exceedingly durable and a necessity for excavations and construction sites. It’s vital to keep them working to the best of their ability. Find out more about the importance of maintaining ground engaging equipment here.

Visual Inspection

Regular maintenance inspections are an effective way to spot worn parts before they begin to interfere with performance. Machinery operators can do a daily visual checklist to spot problems such as:

• Uneven wear and tear to edges, adaptors, or buckets
• Loose or absent hardware, such as adaptor covers or bolts
• Cracks or damage to welded areas

Visual inspections can help determine wear patterns, as well, which can be vital if there is a more optimal solution for preventing damages. Analyzing wear patterns can spot whether an operator is mishandling the equipment, if there could be a better tool for the terrain, or if the wear and tear is to be expected.

Prevention

If you notice any damage or wear, it’s vital to replace or repair parts as soon as possible. Acting fast can help minimize downtime. Even though you will incur some costs from repairing or replacing parts and temporarily halting work, waiting will result in more extended downtimes and more expenses.

Keeping spare parts, such as bucket teeth, that often see damage onsite can help expedite the repair process and prevent the temptation of working with compromised parts. Supervisors should train operators and other workers on how to replace or repair compromised components.

Replacement Schedules

The various parts of ground engaging equipment have recommended replacement schedules; it’s essential to stick to these guidelines to prevent damage. Operators and engineers can also rotate equipment parts and bits to extend the lifespan, but again, you can avoid costly expenses by adhering to the manufacturer’s recommendations.

Understanding the importance of maintaining ground-engaging equipment can help lower costs incurred from extended downtimes, prevent expensive repairs, and improve performance at the job site.

Find out more about maintaining and replacing construction equipment wear parts by exploring the blogs at Cast Steel Products!

Choosing a new mill lining system is a vital decision. As the main power behind grinding, the mill liner plays a crucial role in protecting the shell from erosion. When mill liners age, they lose their ability to grind minerals efficiently. Replacing your mill liner is crucial maintenance that needs to happen routinely.

Price isn’t the only factor in finding a new mill liner. There are several vital considerations when choosing a new mill lining system. Here are a few of them.

Optimization

Searching for steel mill liners can be an arduous process. Finding a liner that’s optimized for your mill will make your mill production more efficient overall. As mill liners age, their ability to grind diminishes. Finding a supplier that can engineer the best fit with the best technology is vital to maintaining your throughput.

With a liner that’s specifically designed for your operating conditions, you will reduce costs incurred with maintenance, and your uptime will increase.

Optimizing the mill liner to your machine increases both output and the quality of the grind due to more efficient charging action. Controlling the charge motion will reduce the erosion on the mill liner. Keeping the grinding on the top and inside of the charge extends the lifetime of the mill liner. The longer the lifetime of your liner, the less maintenance you’ll need, and the more you can maximize your uptime.

Maintenance

One of the main considerations when choosing a new mill lining system is your maintenance schedule. Reducing the maintenance for your mill increases your output by reducing mill stoppages. Replacing a mill liner means stopping production, and with a suitable material and the correct fit, your mill liner will need less upkeep. It’s essential to find a liner that will fit into your production schedule.

Choosing a mill liner that is optimized to your machine’s specifications will increase the product grind quality.

Cast Steel Products creates custom mill liners with extended lifetimes that deliver minimal maintenance stoppages and optimization that increases output with proprietary technology. Contact us with any questions—we’re here to help!

The relationship between a metal casting supplier and the manufacturer is essential. Whether your company is improving on the design of an old product or beginning in metal manufacturing, searching for the right foundry is a process that calls for some scrutiny.

Here are common mistakes to avoid when hiring a new casting supplier.

Lowest Bid

An inexpensive supplier can be enticing to your bottom line. But choosing a foundry based on the lowest bid could cause serious problems, such as winding up with a defective product. Be sure to research the supplier’s reputation. Some considerations to keep in mind include:

• What are past and current customers’ relationships with the supplier like?
• Will the supplier release and discuss complaints they’ve had?
• Is their customer service attentive to you as a prospective client?

Biggest Supplier

One of the easiest mistakes to avoid when hiring a new casting supplier is understanding that bigger doesn’t necessarily mean better. Name recognition might give you a false sense of competence. Even though larger foundries can provide each client face time, they may not necessarily do so. You might end up feeling more like a number and less of a client.

Hiring Locally

Searching for a foundry in your community can be a great way to support your city, but it could limit your options. A supplier that offers a better fit or materials might be somewhere outside your town. Even though hiring locally will provide faster shipping and in-person inspections, the convenience will mean nothing if the quality of your product is lacking.

Finishing

To lower costs, ordering your pieces raw or unfinished (without drilling, boring, facing, or tapping) could be an option to look for with a metal casting supplier. But raw finishes require that you secure outsourced CNC machining. This leaves you with the responsibility of juggling the logistics of multiple suppliers. So, be sure to find a foundry with consolidated machining and finishing.

Simplify your search for heavy steel casting manufacturers, and contact Cast Steel Products today!