Background
- Customer from the agro farm machinery industry approached AMSOL for development ofnew parts using investment casting methods.
- The parts needed to meet stringent durability and precision requirements for demandingagricultural applications.
Customer Requirement
- Develop parts with high dimensional accuracy, corrosion resistance, and mechanicalstrength suitable for heavy field use.
- Achieve cost-effective manufacturing while maintaining quality and timely delivery.
AMSOL’s Understanding and Approach
- AMSOL team thoroughly analyzed the customer’s application, operating environment, andfunctional requirements.
- Based on usage and load conditions, suggested appropriate metal material grades (such as4140 alloy steel or stainless steel variants) for optimal strength and wear resistance inagricultural settings.
- Recommended Shell Mould Casting process over conventional investment casting due tobetter process economics, suitability for batch sizes, and dimensional accuracy.
Shell Mould Casting Process Advantages
- Uses a resin-bonded sand mould that offers superior surface finish and tight control oftolerances.
- Ideal for medium to large complex parts with good reproducibility.
- Faster mould preparation and shorter cycle times compared to investment casting.
- Reduced tooling and material costs, providing overall manufacturing cost benefits.
Cost Savings and Efficiency
- AMSOL successfully reduced the customer’s production costs by approximately 35% below their expectations compared to earlier casting or fabrication methods.
- Optimized process parameters, including material utilization and heat treatment cycles,further enhanced cost efficiency.
Quality and Performance
- Cast parts met or exceeded customer requirements for mechanical strength, surface finish,and dimensional accuracy.
- Durable parts designed to withstand abrasive soils, moisture, and harsh outdoor conditionstypical in agro machinery.
Business Impact
- Strengthened AMSOL’s relationship with the agro machinery customer by providing aninnovative, cost-effective solution.
- Enabled customer to improve product performance and reduce overall manufacturing costs.
- Enhanced AMSOL’s footprint in agricultural sectors by delivering reliable precision castingswith innovative processes.