Farrar Corporation

FARRAR FOUNDRY EQUIPMENT

Farrar Corporation, located in Norwich, Kansas, offers comprehensive facilities combining all the services of a machine shop and ductile iron foundry to meet the needs of our customers. This unique combination works well for the customers to maximize efficiency and minimize cost of manufacturing. Versatility and full service are our keys to efficiency and customer satisfaction. We can help you design a part, build patterns and machine tooling, pour castings and machine them to a finished product all at one location. Let us help you solve your design, material, casting, machining, assembly, quality and delivery problems.

Pattern Shop Click on logo for more info.	The Farrar Corporation pattern shop combines years of experience with current computer technology to produce high quality patterns and core boxes. A computerized solid model of the casting can be created with “SolidWorks” software. This model can be used to produce a master pattern using rapid prototyping technology or to aid in developing the machining programming through the use of “Mastercam” software. The same solid model is often used with AFS solidification simulation software to help identify and eliminate problem areas in the casting before it ever goes to the foundry. These techniques are often used to help our customers convert weldments and forgings to ductile castings. Pattern shop equipment includes 1 Hurco Hawk 5M CNC milling machine, 1 Okuma Cadet L1420 CNC lathe and 1 Mori-Seiki SV-500 CNC vertical machining center with a 30 station automatic tool changer. Patterns are stored in a separate building from the foundry. Each storage location is catalogued in the computer for easy retrieval. Patterns are inspected and repaired before and after production for extended life and to insure only good parts are produced.
Capacity Available	Plant is currently designed to handle up to 60 tons melt per day on a two shift basis. Anticipated expansion to 120 tons melt per day on a two shift basis. Foundry new in February, 1976-49,000 square feet. Specialize in castings weighing from ounces to 65 pound.
Cleaning Room	1 Setco single end snag grinder; 4 Fox single end snag grinders; 1 Wheelabrator with skip loader.
Core Department	2 Redford coreblowers for Iso-cure; 1 Beardsley & Piper CB 15 semiautomatic coreblower for ISO-cure; 2 Dependable shell core machines (manual); 1 SF6CA Beardsley & Piper shell core machine (automatic); 1 Shalco U-180 Shell core machine (automatic).
Material Poured	100% ductile iron of the following grades; 60-40-18, 65-45-12, 80-55-06, 100-70-03. NOTE: All grades available as cast depending on specific casting size. In certain cases additional alloying or heat treating may be required. All grades of Austempered Ductile Iron (ADI).
Melting Department	2 Brown Boveri IT5 2200 KW coreless induction furnaces with one power supply, melt capacity 4.8 tons/hour; 1 Gaylord charge dryer; 3 ton overhead bridge crane for charge makeup and raw material handling. All raw materials are stored indoors.
Molding Department	Two (2) Roberts Sinto FBN-2S, 20 X 24 flask, automatic molding machines, with variable cope and drag heights: One (1) Roberts Sinto FBM-1, 14 X 19 flask, automatic molding machine with variable cope and drag heights: 75B Beardsley and Piper Speedmullor with Hartley Controls.
Pouring Floor	All molds from Roberts Sinto on Vulcan Tru-Flo II automatic mold handling systems. All dumped molds conveyed through shake-out by General Kinematics oscillating conveyors; 1 General Kinematics Vibra Drum; 1 General Kinematics Screener Seperator.
Quality Control Equipment	1 Leco GDS-400A atomic emission spectrometer with 15 standard analytical channels, 1 Melt Lab carbon & silicon analyzer, Metallographic polishing equipment, 1 Nikon microscope, 1 King tester Brinell hardness machine, 1 Pin-Brinell hardness tester, sand characteristics tested automatically on every load of sand with Hartley Controls, complete chemical analysis ran every hour on the iron in the furnace, carbon and silicon checked at furnace prior to tapping, and each ladle is checked for nodularity.