Robotic Sawing

Robotic Sawing Systems for Foundry Castings
ATD Engineering & Machine develops custom robotic sawing solutions for foundries that need to automate casting cutting and degating operations. Complex casting geometries and difficult-to-access cut locations can make manual sawing challenging. ATD evaluates each application to determine a suitable combination of industrial robotics, sawing equipment, and workpiece positioning. With experience in both part-to-media and media-to-part arrangements, ATD can develop a robotic cutting casting solution around the part geometry, required cuts, and production process.

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Robotic Sawing Systems for Foundry Castings

pRODUCT oVERVIEW

ATD Engineering & Machine develops robotic saw systems for foundry applications that require controlled cutting of castings. System development considers the relationship between robot reach, saw access, workpiece orientation, and the cutting sequence. These factors help establish how the robot and cutting equipment should interact throughout the operation. ATD’s experience with custom sawing machinery supports the development of automated casting sawing solutions for specific production requirements, including applications where casting geometry or cut accessibility calls for a specialized equipment arrangement.

Key Features of ATD Robotic Sawing Systems

ATD combines robotic automation with sawing equipment configured for foundry casting requirements. Depending on the machine design, the system can incorporate the following features:

  • Part-to-Media and Media-to-Part Configurations: ATD supports both arrangements for robotic sawing. In part-to-media sawing, the robot moves the casting toward a stationary saw. In media-to-part sawing, the casting is positioned while the saw moves toward the required cut location. Video of both configurations in operation is available below.
  • Carbide-Tipped Saw Blades and Spindle Assemblies: ATD’s sawing equipment can incorporate carbide-tipped circular saw blades mounted on heavy-duty spindle assemblies. Blade selection depends on the casting material, dimensions, and cutting requirements.
  • Casting Fixtures and Hydraulic Clamping: Dedicated fixtures locate and secure castings during cutting. Depending on the equipment configuration, hydraulic clamping can help hold the workpiece in position throughout the sawing sequence.
  • Horizontal, Vertical, and Inclined Saw Motion: ATD’s sawing equipment can accommodate different table-motion arrangements, depending on the machine design. These options allow the equipment layout to be configured around workpiece positioning and the required cutting approach.
  • Integration with Robotic Finishing Cells: An automated casting sawing system can be integrated with other foundry equipment, including trim presses and material-handling systems, where the production sequence and system design support integration.

Gate Removal

Gates connect a casting to the metal-delivery system and may need to be cut away after casting. A robotic saw can be configured to present the casting to the blade or position the saw relative to a secured workpiece, depending on the required cut and system arrangement.

ATD Engineering & Machine evaluates robotic sawing for foundry operations based on casting geometry, required cut locations, and production needs. Depending on the application, robotic systems can support the following operations:

Robotic Sawing Applications

Automated Casting Degating

Automated casting sawing can be considered for production lines that require repeated gate, riser, or sprue removal. Depending on the casting and system layout, the robot can present the part to a stationary saw or work with a configuration in which the saw moves toward the casting.

Riser Removal

Risers supply molten metal during solidification and may require separation from the casting after production. Robotic sawing can automate this operation when the riser location, casting geometry, and blade access are suitable for the proposed cutting sequence.

Repetitive Production Cutting

Foundries processing recurring casting designs may benefit from programmed sawing sequences and dedicated workholding arrangements. Suitable fixturing helps establish a consistent part position, while the robot follows the defined cutting sequence. Actual repeatability and production rates depend on casting variation, fixture design, cutting requirements, and part-handling time.

Sprue and Runner Cutting

Sprues and runners form part of the casting’s metal-delivery system. Robotic cutting casting applications can use programmed movements to position the workpiece or saw for the required cuts. The equipment arrangement depends on the attachment locations, casting dimensions, and accessibility of each cut.

Factors Evaluated for Robotic Sawing System Design​

Casting Geometry

Assess the casting’s dimensions, shape, and contours to determine robot access and suitable workpiece positioning.

Saw and Blade Selection

Determine suitable sawing equipment and blade specifications based on the casting material, dimensions, and cutting requirements.

Cut Locations and Orientation

Identify the required separation points and cutting angles to establish the saw approach and cutting sequence.

Workholding and Clamping

Establish how the casting will be located and secured to maintain its position during the cutting operation.

Robot Reach and Payload

Evaluate whether the robot can access the required cutting positions while handling the casting or operating within the proposed system configuration.

Cell Layout and Integration

Assess equipment clearances, part transfer, and connections with other production machinery to determine how the robotic sawing system will fit into the foundry’s workflow.

Need a Robotic Saw for Casting Degating?​

ATD Engineering & Machine develops robotic sawing systems for foundries that need to automate gate, riser, and sprue removal. Our team can evaluate your casting geometry, cut locations, part-handling requirements, and production volume to determine a suitable robotic sawing configuration.

Share your casting drawings and cutting requirements with ATD to discuss saw selection, workpiece positioning, and robotic integration for your application.

Contact ATD Engineering & Machine to discuss your robotic sawing system.

FREQUENTLY ASKED QUESTIONS

  • A robotic saw uses an industrial robot to control the movement of the casting or coordinate the cutting operation. An automatic degating saw may use a dedicated machine cycle to remove gates and risers without requiring a robot. The appropriate system depends on casting complexity, cutting requirements, and production needs.

  • Robotic sawing may be suitable for cast iron, steel, aluminum, and other cast metals, provided the saw, blade, spindle, and cutting parameters are appropriate for the material. The specific alloy, casting dimensions, and required cut quality should be evaluated before selecting the equipment.

  • Yes, a robotic sawing system may accommodate multiple casting designs when the robot program, fixtures, and cutting setup support the required variations. Changeover procedures and fixture compatibility should be considered when evaluating a system for a product family.

  • The process typically involves reviewing casting drawings or CAD models, defining the cutting sequence, establishing robot and saw movements, and checking for potential collisions. Programming and simulation can help assess the proposed sequence before physical trials validate the setup.

  • Robotic sawing systems require safeguards appropriate to the cutting hazards, including blade contact, flying debris, and workpiece movement. Risk assessment may determine the need for guarding, interlocked access doors, emergency stops, and other protective measures based on the complete system design.

  • Yes, integration may be possible when the robot, saw, material-handling equipment, and existing production controls can operate together. A feasibility assessment should consider available floor space, part-transfer methods, control interfaces, and the sequence of upstream and downstream operations.

  • Useful information includes casting drawings or CAD files, material specifications, required cut locations, expected production volume, current cutting methods, and any cycle-time or part-handling requirements. These details help an equipment manufacturer assess feasibility and develop an appropriate system proposal.