Sawing and Cutting

Custom Degating Saws for Foundry Casting Operations

ATD Engineering & Machine designs and builds custom degating saws for removing gates, risers, and sprues from castings. Our foundry sawing equipment is engineered around the casting, required cut locations, and production process. From standalone saw machines to robotic sawing and integrated casting-finishing cells, ATD works with foundries to determine an appropriate equipment configuration for their application.

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pRODUCT oVERVIEW

Custom Casting Degating Equipment

ATD Engineering & Machine manufactures casting degating equipment for high-production applications. The machine configuration can be tailored to the required table movement, fixture design, and cutting process. ATD can also incorporate custom features and select hydraulic, pneumatic, or servo-electric drives as appropriate for the application. For operations that require more than a standalone saw, ATD can integrate sawing equipment into a broader casting-finishing cell. Depending on the project, that cell may include robotic part handling, a trim press, or other ancillary equipment.

ATD evaluates each casting’s geometry and cutting requirements to determine a suitable saw and fixture configuration.

    Key Features of ATD Sawing and Cutting Equipment 

    Casting-Specific Fixtures: ATD designs custom fixtures around the casting and its required cut locations. Nesting features help locate the part, while the fixture establishes its position for the cutting sequence.
  
    Hydraulic Clamping: The existing ATD saw design uses hydraulic clamps to hold castings against the fixture’s nesting features during cutting. The clamping arrangement is designed around the requirements of the specific part and machine.
  
    Heavy-Duty Saw Spindle Assemblies: ATD’s typical saw machines use carbide-tipped circular saw blades supported by heavy-duty spindle assemblies. The blade and spindle arrangement is selected as part of the equipment design for the cutting application.
  
    Interchangeable Fixtures: Fixtures bolt to the machine’s moving table and can be interchanged. This supports equipment setups where different casting fixtures are required, subject to the machine and application design.
  
    Flexible Table Orientation: The moving table can be configured to operate horizontally, vertically, or on an inclined plane. The suitable arrangement depends on the casting geometry, cut orientation, and machine layout.
  
    Multi-Part Fixturing: Fixtures can be configured to cut single or multiple castings per cycle. Dual-part (or multi-station) configurations increase throughput for high-volume applications where cycle time is a priority.
  
    Flip-Up Guard Door: ATD's saw machines can incorporate a flip-up guard door for operator access to the cutting area, supporting safe loading, unloading, or maintenance without a full enclosure teardown.
  
    Chip and Scrap Evacuation: ATD's saw machines can incorporate chip conveyors to clear cutting debris from the work area, supporting continuous operation in high-production applications.
  
    Application-Specific Drives and Features: ATD can customize equipment using hydraulic, pneumatic, or servo-electric drives. Additional features, including saw-blade lubrication and lubrication for the linear bearing system, can also be incorporated where required.
  
    Robotic and Finishing-Cell Integration: ATD can supply sawing equipment as a standalone machine or integrate it into a casting-finishing cell. Its robotic sawing experience includes both part-to-media and media-to-part arrangements, selected according to the casting and application.

Image Captions

Dual-station incline saw with integrated chip conveyor

Vertical saw with flip-up guard door

Vertical saw motion with casting fixture on a flip-up table

Applications of Foundry Sawing Equipment

ATD’s foundry sawing equipment is designed for casting-cutting applications where the part, cut locations, and production requirements determine the machine configuration.

Gate Removal

Gates connect a casting to the metal-delivery system used during casting. After the casting has been produced, these connections may need to be cut away. A custom degating saw can be configured to position and clamp the casting so the blade follows the intended cut location.

Repetitive Production Cutting

When the same casting is processed repeatedly, a dedicated fixture can help establish a consistent part position for the programmed or machine-defined cutting sequence. Hydraulic clamping holds the casting in place during the operation.

For repetitive production, the fixture and machine should be designed around the specific casting and the sequence of cuts required. The actual production rate depends on the part, number of cuts, handling requirements, and machine configuration.

Riser Removal

Risers provide a reservoir of molten metal during solidification. Once the casting is complete, riser material may need to be separated from the finished part. ATD’s runner and riser removal equipment can be designed around the casting geometry and the required separation points.

Robotic Casting Degating

Some castings are complex or difficult for an operator to handle during sawing and degating. ATD offers robotic sawing solutions for these applications.

Depending on the project, the robot can present the casting to the saw, or the system can be arranged so the saw is presented to the casting. The choice depends on part geometry, cutting access, handling requirements, and cell layout.

Sprue Removal

Sprues are part of the casting’s metal-delivery system and may require removal after casting. Custom casting cutting equipment can hold the part in a defined position while the saw cuts at the designated location. The machine arrangement depends on the sprue position, casting shape, and access required for the cut.

A foundry degating saw incorporated into a robotic cell can also form part of a broader finishing process. ATD has integrated degating saws into casting-finishing cells using robotic part presentation or fixtures and clamping on a belly saw.

Factors Evaluated for Automatic Degating Saw Selection

Casting Geometry

Assess the casting’s shape, dimensions, and features that may affect saw access and positioning.

Part Positioning and Fixturing

Evaluate how the casting will be held and positioned to maintain consistent alignment during sawing.

Gate and Riser Locations

Identify the attachment points and required cut locations to establish the cutting approach.

Automation and Integration

Determine whether a standalone saw, an automated sawing system, or a robotic cell best suits the production workflow.

Cutting Requirements

Determine the number, orientation, and accessibility of cuts needed to separate gates, risers, and sprues.

Discuss Your Casting Sawing Requirements with ATD

ATD Engineering & Machine develops custom sawing systems for foundries with specific part-handling, cutting, and production needs. Equipment configurations can include dedicated fixtures, customized table arrangements, and integration with robotic systems or casting-finishing cells.

Provide your casting specifications and production requirements to help our team assess a suitable solution for your operation.

Contact ATD Engineering & Machine to discuss your project.

FREQUENTLY ASKED QUESTIONS

A degating saw is a cutting machine used to remove gates, risers, or sprues from metal castings. ATD Engineering & Machine builds custom sawing equipment designed around the casting, required cut locations, and production process.
The suitable casting depends on the machine design, fixture, cutting requirements, and part geometry. ATD evaluates these factors to determine an appropriate saw configuration for the application.
A standalone saw performs the cutting operation using its machine and fixture arrangement. A robotic sawing system incorporates a robot to present the casting to the saw or to support the selected cutting arrangement. ATD offers both standalone and integrated equipment configurations.
A custom fixture uses nesting features to locate the casting in the intended position. Hydraulic clamps hold the casting against those features during cutting, helping establish the position of the part for each cut.
Yes. ATD states that its saws can be incorporated into finishing cells with a robot, trim press, or other ancillary equipment. The configuration depends on the production process and integration requirements.
Important considerations include casting geometry, gate and riser locations, required cut positions, fixture design, table orientation, clamping, and whether the saw will operate as a standalone machine or as part of an automated cell.
ATD manufactures custom sawing equipment and can integrate saws with robotic and other finishing equipment. The appropriate level of automation and machine configuration depends on the casting and the requirements of the application.