Customer Requirement & Initial Situation
- A global OEM in the mining industry was producing a Balancer part using welded assemblies.
- Their challenges with welded construction:
- o Multiple fabrication steps → longer cycle time.
- o Higher labor & inspection costs.
- o Weld joint weaknesses under heavy loads.
- o Inconsistent quality due to manual processes.
Limitations of Welded Parts
- High Manufacturing Time: Cutting, welding, grinding, and inspection required for each part.
- Structural Weakness: Welded joints had stress concentration points.
- Higher Rejection Rate: Dimensional variations from multiple processes.
- Cost Inefficiency: More operations = higher production cost.
AMSOL’s Engineering Solution
- Proposed process conversion: Replace welded construction with integrated casting design.
- Benefits of integrated casting:
- o Higher strength due to monolithic structure (no weld joints).
- o Reduced cycle time by eliminating multiple fabrication steps.
- o Better dimensional accuracy with casting + machining.
- o Cost savings from simplified manufacturing.
Execution Steps by AMSOL
- Design Feasibility Study
- o Redesigned welded assembly into a castable geometry.
- Pattern & Tooling Development
- o Created robust casting pattern for repeatable production.
- Casting Production
- o Manufactured balancer as a single integrated casting.
- CNC Machining & Finishing
- o Ensured dimensional tolerances and surface finish.
- Testing & Validation
- o Verified mechanical properties & load performance under mining application conditions.
- Customer Approval
- o Prototype approved, leading to series production.
Achieved Results
- Reduced manufacturing process time significantly.
- Improved strength & reliability compared to welded assemblies.
- Faster production cycle, enabling higher volumes.
- Consistent quality with reduced rejection rate.
- Cost-competitive solution for OEM customer.
Customer Benefits
- Higher equipment durability in demanding mining environments.
- Optimized production schedule with faster deliveries.
- Reduced maintenance & downtime due to stronger parts.
- Long-term savings from lower rework and inspection costs.
AMSOL Value Proposition
This case highlights AMSOL’s ability to:
- Convert complex welded assemblies into simplified cast designs.
- Deliver higher strength, lower cost, and faster production.
- Support global OEMs with process innovation and 360° manufacturing solutions.