Testing Results

The test has two phases:

Confirmation of the device’s (matchplate) function,
Confirmation that the foundry has adequate space and supplies to successfully produce the sixteen (16) C-clamps.

Phase 1 Testing:

The testing of the matchplate function, as originally built, was done on April 4, 2017 from 1pm to 5pm in the afternoon at the Central Washington University (CWU) foundry during a Metal Casting/Foundry class. All resources and required personnel to operate the furnace, pouring crane, and sand mixer were on hand and all required protective clothing was worn.

The initial testing resulted in some service defects in the C-clamps these flaws were believed to be operator error by not packing the green sand with enough crushed walnut shells to create a smooth surface.However, these C-clamps will be handed off to the machine shop to complete the C-clamps to functioning tools.

Phase 2 Testing:

The testing of the facility inventory and space needs at the CWU foundry was completed on April 6, 2017.The number of C-clamps formed during this phase of testing was reduced to two flasks which produced 4 C-clamps because of the lack of supplies available at the foundry.It was agreed that by producing 4 C-clamps the inventory and space needs could be extrapolated to the full production run of 16 C-clamps.

During the testing phases, it was discovered that establishing a datum for the sprue well placement prior to packing the matchplate with sand was needed.If this datum is not established and the sprue well diameter is enlarged or re-punched it compromises the C-clamp.If the sprue well is enlarged it causes turbulence with the pour which results in a sub-standard product.

It has been noted in the instructions to the University that the sprue well datum must be established prior to packing the matchplate with sand.

A test C-clamp was delivered to the machine shop which is the final step of this project.

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