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Isolated casting cut off

The task

Cutting runners and risers from cast components.

The problem

In a small alloy steel foundry, runners and risers used to be cut from castings using 225 mm (9 in) hand-held disc cutters. Over a typical working cycle, this operation produced an average vibration magnitude of more than 5 m/s2. Operators could have been exposed to this vibration for up to 5 hours a day, giving a potential vibration exposure well above the exposure action value and likely to reach the limit value. The eight workers in the fettling area used 25 000 cutting discs per year. The work also resulted in high noise exposure and a lot of manual handling.

The solution

As part of a general programme to improve ergonomics and reduce vibration exposure in the fettling area, the company bought an enclosed remote-controlled cut-off machine. The casting is mounted in a simple fixture and cut by a large abrasive disc on a hydraulic arm. The operator watches the cutting through a window in the enclosure and does not come into contact with any vibrating components.

Cutting off a casting with a hand-held tool

Cutting off a casting with a hand-held tool

Automatic cut-off machine showing a casting in a fixture

Automatic cut-off machine showing a casting in a fixture

The cost

Disc costs have reduced by approximately 80%. The machine paid for itself in 4 years both through improved productivity and greatly reduced disc consumption.

The result

  • The operators are not exposed to any vibration.
  • It has helped in the programme to reduce back injuries at the foundry.
  • The exposure to noise, dust and fumes has reduced.
  • The risk of injury by contact with the cutter or hot metal is reduced.
  • More work can be processed by the same number of workers.

Case courtesy of Terrill Bros. (Founders) Ltd

Link URLs in this page

  1. Vibrationhttps://www.hse.gov.uk/vIBRAtIon/index.htm
  2. Hand arm vibrationhttps://www.hse.gov.uk/vIBRAtIon/hav/index.htm
  3. About this websitehttps://www.hse.gov.uk/vIBRAtIon/hav/about.htm
  4. Key messageshttps://www.hse.gov.uk/vIBRAtIon/hav/keymessages.htm
  5. Worried about your handshttps://www.hse.gov.uk/vIBRAtIon/hav/yourhands.htm
  6. Overview - Advice for employershttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/index.htm
  7. Employers responsibilitieshttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/responsibilities.htm
  8. Assess riskhttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/assessrisks.htm
  9. Overview - How to protect workershttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/protect.htm
  10. Control riskhttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/controlrisks.htm
  11. Information and traininghttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/information.htm
  12. Health surveillancehttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/healthsurveillance.htm
  13. Overview - Good practicehttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/index.htm
  14. Overview - Foundrieshttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/index.htm
  15. Eliminate fettling by improving casting qualityhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/fettlingelimination.htm
  16. Machining as a substitute for fettlinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/machining.htm
  17. Automatic fettlinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/automaticfettling.htm
  18. Jig-mounting of grindershttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/jigmounting.htm
  19. Semi-automatic cut off machinehttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/cutoffmachine.htm
  20. Isolated casting cut offhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/isolatedcasting.htm
  21. Installation of hydraulic cropping machinehttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/hydrauliccropping.htm
  22. Shell knockout 1https://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/castingshell.htm
  23. Shell knockout 2https://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/contactcastingshell.htm
  24. Hydraulic pushouthttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/furnaceliningremoval.htm
  25. Ladle slag chippinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/foundries/chippingslag.htm
  26. Overview - Constructionhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/index.htm
  27. Preparing a code of practicehttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/tunnelling.htm
  28. Construction Industry Council guidancehttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/cicguidance.htm
  29. Mounted breakerhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/mountedroadbreaker.htm
  30. Directional drillinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/directionaldrilling.htm
  31. Crushing concretehttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/crushingconcrete.htm
  32. Bursting concretehttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/burstingconcrete.htm
  33. Diamond wire cuttinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/diamondwire.htm
  34. Water jettinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/waterjetting.htm
  35. Codes of Practice from the Water Jetting Associationhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/codeofpractice.htm
  36. Grit blastinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/gritblasting.htm
  37. Paint-on retarderhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/paintonmaterial.htm
  38. Special formworkhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/construction/specialformwork.htm
  39. Overview - Steel fabricationhttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/fabrication/index.htm
  40. Machininghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/fabrication/cncmachining.htm
  41. Laser cuttinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/fabrication/lasercutter.htm
  42. Plasma cuttinghttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/fabrication/plasmacutting.htm
  43. Noise reduction in the ship repair industry – research report 1992https://www.hse.gov.uk/vIBRAtIon/hav/campaign/fabrication/noisereduction.htm
  44. Abrasive blastershttps://www.hse.gov.uk/vIBRAtIon/hav/campaign/fabrication/abrasiveblasters.htm
  45. Overview - Regulationshttps://www.hse.gov.uk/vIBRAtIon/hav/regulations.htm
  46. Inspector briefinghttps://www.hse.gov.uk/vIBRAtIon/hav/inspectorbriefing.htm
  47. Overview - Resourceshttps://www.hse.gov.uk/vIBRAtIon/hav/information.htm
  48. Publicationshttps://www.hse.gov.uk/vIBRAtIon/hav/publications.htm
  49. Researchhttps://www.hse.gov.uk/vIBRAtIon/hav/research.htm
  50. Statisticshttps://www.hse.gov.uk/vIBRAtIon/hav/statistics.htm
  51. Useful linkshttps://www.hse.gov.uk/vIBRAtIon/hav/links.htm
  52. Vibration calculatorhttps://www.hse.gov.uk/vIBRAtIon/hav/calculator-guide.htm
  53. Overview - Case studieshttps://www.hse.gov.uk/vIBRAtIon/hav/casestudies/index.htm
  54. (HAVS) in two motor companieshttps://www.hse.gov.uk/vIBRAtIon/hav/casestudies/enforceex.htm
  55. Monitoring exposure to Hand-Arm Vibrationhttps://www.hse.gov.uk/vIBRAtIon/hav/casestudies/mhav-carlwest.htm
  56. Overview - Supply project eventshttps://www.hse.gov.uk/vIBRAtIon/hav/project-events.htm
  57. Controlling vibrationhttps://www.hse.gov.uk/vIBRAtIon/hav/controlling-vibration.htm
  58. Q & A on hand toolshttps://www.hse.gov.uk/vIBRAtIon/hav/hand-tools-qa.htm
  59. Q & A on using a vibration consultanthttps://www.hse.gov.uk/vIBRAtIon/hav/qa-consultant.htm
  60. Q & A on health surveillancehttps://www.hse.gov.uk/vIBRAtIon/hav/qa-surveillance.htm
  61. Hand-arm vibration at work: A brief guide https://www.hse.gov.uk/pubns/indg175.htm
  62. Advice for employershttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/index.htm
  63. Regulationshttps://www.hse.gov.uk/vIBRAtIon/hav/regulations.htm
  64. How to protect workershttps://www.hse.gov.uk/vIBRAtIon/hav/advicetoemployers/protect.htm
  65. Constructionhttps://www.hse.gov.uk/construction/index.htm
  66. Engineeringhttps://www.hse.gov.uk/engineering/index.htm
  67. Motor vehicle repairhttps://www.hse.gov.uk/mvr/index.htm
  68. Noisehttps://www.hse.gov.uk/noise/index.htm
  69. Quarrieshttps://www.hse.gov.uk/quarries/index.htm
  70. Agriculturehttps://www.hse.gov.uk/agriculture/index.htm

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2021-05-20