Arts and Crafts : manufacturing ashtrays foundry

 

I offer you today first episode a small series of photos about the preparation of a Gala, and not just any : that of Arts and Medithirds of Lille. Ce gala, bringing about a year 4000 people in school, has many features. We will see in this series how these features make this holiday a very special event. Having had the chance to be responsible for organizing the gala there a few years, it is with great pleasure to be back this year to attend the preparation for you to share some secrets.

Ashtrays, traditional objects Gala

A tradition of the gala is to distribute to its participants objects made in the workshops of the school by the students themselves. These objects are always ashtrays, although sometimes they are difficult to use as such. This may seem strange as “gift” de gala, but going further than the very purpose of the object, this is the phase of design and construction that will have meaning. Students organize themselves to propose a project that holds up to their teachers manufacturing. The ashtray is made either by machining, soit one fonderie ou bien en forge. These are workshops that have always existed in the school of Arts and Crafts, but maybe one day will ashtrays made in 3D printing !

This project will develop the leadership students, and cohesion : an achievement of this magnitude (most 700 units are generally made) indeed requires a significant investment of a large number of students ! The project is still supported by teachers, because it allows to combine the projects “extra-scolaire” students to the teaching of school. What more ?

The project Fignoss 2013

This year, to match the theme of the gala in connection with antiquity, Team ashtrays (Rhinestone cendar's) decided to make a hollow amphora. A CAD drawing was created, then all calculations foundry were performed to determine the method of casting. An unusual process was chosen to meet the specifications : the inverted casting process (I'll explain in detail its principle in photo captions). The mold was made in collaboration with Professor machining, and required many hours of work (carried out during hours of course !). Congratulations to the team's cendar anyway, because as you will see the result is spectacular !

Foundry arts and crafts - Overview of Arts and crafts of Lille foundry workshop, which are made every year ashtrays for the Gala des Arts et Métiers : the Fignoss.

Overview foundry Arts and Crafts Lille, which are made every year ashtrays for the Gala des Arts et Métiers : the Fignoss.

Foundry arts and crafts - Empreinte du cendrier dans le moule dit en "coquille", in which will be poured molten aluminum

Footprint in the ashtray said mold “shell”, in which to cast molten aluminum

Foundry arts and crafts - The mold is in two parts, auxquelles s'ajoutent une "broche" on the upper part of the amphora, to improve the surface condition of the mouth of the.

The mold is in two movable parts, plus one “brooch” on the top of the jar, for improving the surface finish of the mouth thereof.

Foundry arts and crafts - Fitting the mold, with its rare specificity in the world of foundry : the ashtray is molded with the technique of reverse. Cette technique permet d'avoir une pièce creuse sans "noyau" in the mold. To achieve the molding, to pour aluminium up to brim into the mould, then return after a few seconds the mold. Aluminium in contact with the mold will be solidified, While the inner, always liquid, out of the mold : we obtain a hollow part !

Fitting the mold, with its rare specificity in the world of foundry : the ashtray is molded with the technique of reverse. This technique allows a hollow without “core” in the mold. To achieve the molding, must pay the aluminum to the brim in the mold, then return after a few seconds the mold. The aluminum in contact with the mold is solidified, while the interior, always liquid, out of the mold : we obtain a hollow part !

Foundry arts and crafts - The assembly is disassembled and checked before the first test.

The assembly is disassembled and checked before the first test.

Foundry arts and crafts - Point central de ce montage de coulage "renversé" : the pivot of the mold.

Central to this casting mounting “overturned” : the pivot of the mold.

Foundry arts and crafts - The aluminium bars are placed near the oven where they will be melted.

The aluminum bars are placed near the oven where they will melt.

Foundry arts and crafts - Mussels ashtrays previous years, many, are always in foundry workshop. If necessary, It is always possible to take a few pieces top !

Mussels ashtrays previous years, many, are still in the foundry. If necessary, it is possible to take a few pieces over !

Foundry arts and crafts - The mold is greased for easy handling.

The mold is greased for easy handling.

Foundry arts and crafts - The mold is heated the gas to 220 ° C for the purposes of the release.

To mold parts, the shell is heated and coated with a special mixture, le poteyage. This will prevent the aluminum to adhere to the mold, and define the surface of the part. The mold is heated with gas up to 220 ° C for the application of release agent.

Foundry arts and crafts - A thermocouple is used to check the temperature of the mold. Ici 212°C : It's still not.

A thermocouple is used to check the temperature of the mold. Ici 212°C : it is not always that.

Foundry arts and crafts - The different parts of the mold must be handled with great care.  Numerous hours of work would be lost if a shock were to deform the gasket.

The different parts of the mold must be handled with great care. Numerous hours of work would be lost if a shock were to deform the gasket.

Foundry arts and crafts - The used coating is here of graphite containing particles with a size of six microns. It is sprayed onto the mold with a special gun.

The release agent used here is graphite containing particles of a size of six microns. It is sprayed onto the mold with a special gun.

Foundry arts and crafts - Projection of graphite release agent on the mold

Projection of graphite release agent on the mold

Foundry arts and crafts - Cendars-AM-Lille-photo-Guilhem-de-Lepinay-19 Foundry arts and crafts - Cendars-AM-Lille-photo-Guilhem-de-Lepinay-21

Foundry arts and crafts - Another coating is prepared for the ladles and tools is not involved in the final State of the room : There is no need to be as fine in these cases there.

Another release agent is prepared for ladles and tools are not involved in the final state of the room : it does not need to be as close in these cases.

Foundry arts and crafts - White release agent is applied to the brush

White release agent is applied to the brush

Foundry arts and crafts - The same, the ladles used to transport aluminum from the crucible to the mold must be heated and poteyees.

The same, ladles used to transport aluminum crucible mold must be heated and poteyées.

Foundry arts and crafts - Cendars-AM-Lille-photo-Guilhem-de-Lepinay-26

Foundry arts and crafts - Brooch, room on the upper part of the amphora, also receives the release agent.

Brooch, from the upper part of the jar, also receives the release agent.

Foundry arts and crafts - Cendars-AM-Lille-photo-Guilhem-de-Lepinay-29

Foundry arts and crafts - The two mold parts subjected to the same treatment.

The two mold parts subjected to the same treatment.

Foundry arts and crafts - The mold is then back on his swing rack.

The mold is then back on his swing rack.

Foundry arts and crafts - All equipment is ready. After a last brief around the barbecue house with Professor foundry, engineering students will be able to test their mold. Outstanding !

All equipment is ready. After a last brief around the barbecue house with Professor foundry, engineering students will be able to test their mold. Outstanding !

Foundry arts and crafts - The temperature will greatly influence the quality of castings.

The temperature will greatly influence the quality of castings.

Foundry arts and crafts - Aluminum is now melting in the oven. More than 700 ° C, must be very careful when handling the molten metal.

Aluminum is now melting in the oven. More than 700 ° C, must be very careful when handling the molten metal.

Foundry arts and crafts - Dressing performers : Leather rigueur !

Dressing performers : Leather rigueur ! Apron and gaiters add to the blue full work.

Foundry arts and crafts - The color should bring molten aluminum, the flow, then recover the surplus to put it back in the oven.

The color should provide molten aluminum, the flow, then recover the surplus to put it back in the oven.

Foundry arts and crafts - Aluminum is poured from the ladle into the hole of the mould, looked at 30 ° C for better metal flow.

The aluminum is poured from the ladle into the hole of the mold, bent at 30 ° to improve the flow of metal.

Foundry arts and crafts - The operation must be performed quickly but without haste : the skin of aluminium, in contact with air, does not fit the mold otherwise damage the properties of the metal.

The operation must be done quickly but without haste : the skin of the aluminum, in contact with air, does not fit the mold otherwise damage the properties of the metal.

Foundry arts and crafts - First amphora output : almost perfect ! The joy of the students is palpable : All their efforts were rewarded with the first successful casting.

First amphora output : almost perfect ! The joy of the students is palpable : All their efforts were rewarded with the first successful casting.

Foundry arts and crafts - The following streams are sometimes little trouble.... It is the job that fits !

Many jars out of the mold without defects, but there are still some small problems… It is the job that fits !

Foundry arts and crafts - De l'aluminium solidifié dans la broche bouche l'orifice de "vidage" of the mold, resulting solid models amphorae, who are suddenly not very economical quantity of metal : They will be recast in the oven.

Of solidified aluminum in the orifice mouth spindle “Dump” of the mold, resulting solid models amphorae, who are suddenly not very economical quantity of metal : They will be recast in the oven.

Foundry arts and crafts - Months of hard work rewarded with a few successful examples of ashtrays.

Months of hard work rewarded with a few successful examples of ashtrays.

Foundry arts and crafts - Le poteyage, planned originally for 200 parts, must be done again before the deadline : This is an opportunity to try to edit it to change the State of surface of the finished part.

Le poteyage, originally planned for 200 parts, must be performed again before the deadline : this is an opportunity to try to change to change the surface of the finished part.

Foundry arts and crafts - Cendars-AM-Lille-photo-Guilhem-de-Lepinay-45 Foundry arts and crafts - Cendars-AM-Lille-photo-Guilhem-de-Lepinay-46

Foundry arts and crafts - Le mouleur "puise" l'aluminium dans le creuset maintenant l'aluminium à plus de 700C.

The caster “draws” aluminum in the aluminum profile crucible to above 700 ° C.

Foundry arts and crafts - L'aluminium est versé dans le moule

The aluminum is poured into the mold

Foundry arts and crafts - Work cleaning the spindle must be performed between each piece : a second pin may be necessary to optimize the production rate ashtrays.

Work cleaning the spindle must be performed between each piece : a second pin may be necessary to optimize the production rate ashtrays.

Foundry arts and crafts - The mold is opened to retrieve the item : here, elle n'est pas complète car un problème est survenu au moment de verser le métal.

The mold is opened to retrieve the item : here, it is not complete because there was a problem when pouring the metal.

Foundry arts and crafts - The mold, véritablement parfait à la première utilisation, ne se comporte pas bien lors de la production : Small changes should be made to optimize production.

The mold, perfected during the first cast, behaves very well in a more sustained production : Small changes should be made to optimize production.

Foundry arts and crafts - Detail of amphora made.

Detail of amphora made. Beautiful performance complexity of the method used and the results obtained for !

Thirty ashtrays have been successfully completed during the first test session. This is far from 700 planned total, but still very good for a first time ! The objective will be surely achieved without problem this year !

Congratulations to all the team's cendar, and good luck for the week of frenzied achievement of 700 ashtrays planned for next week !

More information on the official website Fignoss Gala : fignoss.gadz.org

The next episode !

The next reports show other aspects of the preparation of the gala arts and crafts, as the organization of students during the week of preparation, and the transformation of the school eg. See you soon !

10 replies
  1. Snoopy says:

    Remarkable work, incredible photos, and clear and concise explanations!

    Congratulations!

    A very good point for the workshops at the Ecole Nationale Superieure des Arts et Metiers!

    Snoopy
    10li210

    Reply
  2. Turlut says:

    Congratulations!
    Congratulations to the team's cendar really sure this year ^ ^
    And congratulations for reporting, it's really great to radiate all this work outside the school (and the way to get the old archis smile ^ ^ M. Costs).

    Turlut
    9Li209

    Reply

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  1. […] Organizer of this year to cover the evening and its organization : Here you will find the article on the manufacture of traditional ashtrays of the Gala, or where the creation of […]

  2. […] the success of the first article about the casting of Arts and Crafts of Lille and its traditional ashtrays, I was […]

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