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Resurrection of a CFEI 100 KVA Induction Furnace

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awemawson:
Ho Ho Steve - you obviously have a career ahead of you on the stage  :lol:

So mangling my brain this afternoon I've produced an embryonic 3D model using Fusion360 - oh boy my head hurts ! It's printing at 20% fill (ie weak) using PETG as it was in the printer. This will let me see if it fits.

I've omitted the unnecessary features - extra  holes and other material reducing measures that were in the original - hence a model to see if it fits !

ddmckee54:
Andrew:

If the part fits, you might want to try increasing the infill and print it again.  It might actually work for a while.

Don

awemawson:
So the 3D print finished after 3 hours 21 minutes last night. It's come out well and it fits.

Not only that I was able to latch and unlatch the mechanism - as someone suggested, one of the lugs on the 'spring pot' pushes the hook latch up when reset. It's the upper single bar not one of the ones that broke off.

I was not at all surprised the the PetG print broke when I tripped the mechanism - in fact it broke just like the original !

I've subsequently noticed that the lugs that broke off were not 'merged' with the main body but rather are intimately close to it, so no reinforcement crosses their junction. Fine for lost PLA casting but no use as a component as is.

awemawson:
Well you can't win 'em all  :bang:

Printing the PETG at a greater density gives it much more likelihood of warping and pulling away from the build table - I have a heated platen on this 3D printer but I forgot to turn it on.

I could see that it was beginning to curl away from the base but hoped that it would stay stuck to the end - no - it became detached and produced a birds nest.

Never mind - I'll do it again tomorrow with the heater on, but the print that I got here demonstrated dramatically more strength due to the 80% fill density (was 20%)  and the fact I merged the lugs into the main body so that they were one entity with the mesh layout running between them.

I suspect a good PETG print will have the strength to do the job, at least for testing, but it becomes quite weak at higher temperature so no good for the final item - that will be lost wax PLA cast in bronze. So PLA versions to be printed as well tomorrow.

djc:
I wonder if it is possible to bypass or reduce the spring force on the ears of the die cast bit.

Drill a hole through the casing concentric to the spring and use a sliding, adjustable stop bolt (maybe with a rubber washer on the outside as a cushion.

Would lumiweld or similar repair the original metal part?

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