{"id":4049,"date":"2018-11-13T11:58:26","date_gmt":"2018-11-13T17:58:26","guid":{"rendered":"https:\/\/dunwoody.edu\/news\/?p=4049"},"modified":"2018-12-11T16:05:43","modified_gmt":"2018-12-11T22:05:43","slug":"foundry-experience-returns-to-dunwoody","status":"publish","type":"post","link":"https:\/\/dunwoody.edu\/news\/2018\/foundry-experience-returns-to-dunwoody\/","title":{"rendered":"Foundry experience returns to Dunwoody"},"content":{"rendered":"

Mechanical Engineering students create aluminum wrenches<\/h3>\n
\n

With the precision of a surgeon, Angela Freeland lifts a 3D printed wrench from a wooden box, packed tightly with a mixture of damp sand and clay.\u00a0 She cracks a wide smile before leaning in to watch her classmate, Daniel Hurd, tap lightly on the white plastic to loosen it \u2013 ever-so slightly \u2013 so he can remove his mold.<\/p>\n

\u201cBoom,\u201d Freeland says. \u201cI\u2019ll take it,\u201d Hurd said.<\/p>\n

The two Dunwoody Mechanical Engineering students are spending the afternoon with their instructor and classmates in the Foundry, learning how to sandcast and make their own aluminum wrenches.<\/p>\n

It is a pain-staking process.<\/p>\n

\"\"
Mechanical Engineering Student Angela Freeland<\/figcaption><\/figure>\n

The sand and clay mixture has to have the right amount of moisture, the plastic pattern cannot have any rough or sharp edges, and the sand must be packed tight around the pattern.\u00a0 The temperature of the molten aluminum must be precise and poured quickly into the molds. If anything is slightly off, the wrench might not turn out, sending students back to square one.<\/p>\n

3D Printing brings changes to the 21st<\/sup> century foundry <\/strong><\/h6>\n

\"\"<\/p>\n

Dunwoody has not had a working foundry in decades.\u00a0 Historically, the foundry was used in limited capacity to cast dead blow hammers and other tools used in the machine shop. With the support from the American Foundry Society<\/a> and Engineering Drafting & Design Assistant Professor Alex Wong, this technology is returning to Dunwoody.<\/p>\n

\u201cThe ability to 3D print patterns has completely changed the industry. A pattern that took days or weeks to build in the past can now be printed in a few hours and prepped for casting the same day,\u201d said E.J. Daigle, Dean of Robotics & Manufacturing.<\/p>\n

The United States ranks third in global casting production, trailing behind China and India. Foundries are struggling to find the next generation of workers.<\/p>\n

Dunwoody is racing to help fill that need.<\/p>\n

Students studying Engineering Drafting & Design, Mechanical Engineering, Machine Tool Technology, Welding & Metal Fabrication, and Design for Manufacturing: 3D Printing, will all use the foundry as part of their course work.<\/p>\n

\"\"
Engineering Drafting & Design students sand cast molds for putters they designed in class with Alex Wong.<\/figcaption><\/figure>\n

Each year Wong has his students design a golf putter for casting as a class assignment. They use Computer-Aided Design (CAD) software to design their putters.<\/p>\n

Before this year the castings were sent to area foundries. Today, students send their designs to one of the 3D printers in the Metrology lab. Hours later, they have a pattern ready to use in the foundry.<\/p>\n

\u201cI like the hands-on process a little bit better because the students see what is involved with making their molds,\u201d Wong said.<\/p>\n

They learn even more when something doesn\u2019t work.<\/p>\n

\u201cWhen you have to sit down and scratch your head a little bit from those tough lessons, it\u2019s frustrating, but the lessons stick a little better,\u201d Wong said.<\/p>\n

\"\"<\/p>\n

Alireza Razavi, Mechanical Engineering Instructor at Dunwoody, says that it is important for a mechanical engineer, who may be involved in manufacturing, to experience casting and be able to observe hardships or defects in the manufacturing processes.<\/p>\n

\u201cThe most important objectives of doing a casting is to see its difficulties and approaches on how to make a better pattern and mold for a better casting,\u201d he said.<\/p>\n

Hands on approach solidifies training<\/strong><\/h6>\n
\"\"
Mechanical Engineering student Angela Freeland frees her aluminum wrench, made in the foundry.<\/figcaption><\/figure>\n

Freeland\u2019s brother and father are both graduates of Dunwoody programs and encouraged her to attend.\u00a0 Initially a Graphic Design major, she switched to Mechanical Engineering, a decision that allows her to better utilize her math skills.<\/p>\n

In the Foundry she is eager to put on the protective suit and get close to the crucible for a front row seat. The thick reflective jacket, chaps, gloves, and helmet will protect her from any molten aluminum that might splatter as it is poured.<\/p>\n

She said it is one thing to have her instructors talk about something during a lecture. \u201cBut actually getting out there and doing the hands-on work and viewing this technology is a real eye-opener,\u201d Freeland said.<\/p>\n

\u201cBeing able to put the suit on, look in there, and have [my instructors] explain it, helps solidify everything I\u2019ve learned over the past few years,\u201d she said.<\/p>\n","protected":false},"excerpt":{"rendered":"

Mechanical Engineering students create aluminum wrenches With the precision of a surgeon, Angela Freeland lifts a 3D printed wrench from a wooden box, packed tightly with a mixture of damp sand and clay.\u00a0 She cracks a wide smile before leaning in to watch her classmate, Daniel Hurd, tap lightly on the white plastic to loosen […]<\/p>\n","protected":false},"author":4,"featured_media":4051,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[178],"tags":[],"class_list":["post-4049","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-student-news"],"yoast_head":"\nFoundry experience returns to Dunwoody<\/title>\n<meta name=\"description\" content=\"Mechanical Engineering students create aluminum wrenches\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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