Aluminum sand casting quality improvement case of products transferred from other companies | Industrial machinery parts
Air leaks due to shrinkage cavities in castings from other companies cannot be stopped. We reviewed the plan and reduced the defect rate of transferred products from 70% to 3%. We have a track record of prototypes from one piece, with 5,000 items across 200 companies.
During the airtightness test after processing, leaks were found, resulting in the parts that had been carefully machined becoming defective. For industrial machine parts cast by another company, the defect rate reached 70%. We received an inquiry under such circumstances. The cause of the leaks was shrinkage cavities. When the thicker sections solidify last, if the supply of molten metal cannot keep up, cavities remain inside. Even if they are not visible on the casting surface, they appear on the surface when machined, creating a pathway for leaks. Since the cause lies in the arrangement of the risers and gates, simply changing the foundry will not resolve the issue. Karmo Casting reviewed the drawings and defective products, and redesigned the process. We verified the solidification sequence and flow of molten metal in advance through casting simulations, and modified the design to ensure that molten metal reaches the thicker sections. We carried out everything in-house, from the production of wooden patterns to casting, machining, and inspection, reducing the defect rate from 70% to 3%. The switch can be made after confirming quality with a single prototype, and factory tours before the contract are also possible. We are offering a free casting defect countermeasure guidebook summarizing the causes and countermeasures for shrinkage cavities, poor metal flow, and cracking. Please download it from the link below.
basic information
【Scope of Services】Production of wooden molds / Design proposals / Casting / Machining / Integrated production of airtightness testing (processing of other companies' cast products is also acceptable) 【Defects Addressed】Shrinkage cavities / Air leaks (countermeasures through proposal review) 【Quality Measures】Preliminary confirmation of solidification and flow through casting simulation 【Lot Size】From 1 piece (switching after quality confirmation in prototype) 【Casting Size】50mm square to 1,000mm square / Minimum thickness 1mm (local) / 1.5mm (overall) 【Supported Materials】 - Aluminum alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B - Copper alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 【Casting Processes】In-house possession of five methods: sand mold / self-hardening / alkaline phenolic / cold box / metal mold 【Machining Equipment】15 units of 5-axis machining centers / 2 gantry-type machines / 3 vertical machines / 2 NC lathes 【Machining Accuracy】Geometric tolerance ±0.03mm 【Inspection Equipment】2 contact-type 3D measuring machines / Non-contact 3D digitizer (deviation 30-80μm) / 3D scanner NIMBLETRACK Gen2 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2
Price information
If you could provide the details of the drawings and the defects (locations of leaks and defect rates), we will provide a free estimate along with a proposal for revising the plan. If you have the actual defective products, it will be easier to identify the cause. Since we design and manufacture molds in-house, we can also complete the mold rework associated with the transfer at one company. You can switch after confirming the quality with prototypes starting from just one piece.
Price range
P2
Delivery Time
OTHER
The prototype will be shipped in a minimum of 2 weeks, and the first order including mold production will take at least 3 weeks. The delivery time for transferred items may vary depending on the review of the plan, quantity, and processing areas, so please let us know your desired switch timing.
Model number/Brand name
AC4CH/AC4C/AC4B/AC4A/AC2A and other aluminum 10 material types (cast products for shrinkage and airtight leakage measures)
Applications/Examples of results
【Applicable Industries】Industrial Machinery / Machine Tools / Agricultural Machinery / Robots / Ships / Railways / Power & Energy / Semiconductor Manufacturing Equipment / Automotive & CASE 【Improvement Case】 ■ Industrial Machinery Parts: Transfer products from other companies (Aluminum sand castings / Air-tight leaks due to shrinkage cavities / Review of design reduced defect rate from 70% to 3%) 【Other Achievements】 ■ Industrial Machinery Parts (AC4CH-T6 / Complex shape with 11 cores) ■ Cylinder Cases for Railway Vehicles (AC4CH-T6 / Complex shape with 6 cores) ■ Aluminum Parts for Ships (AC2A-T6 / Small size, high quantity) 【Used in Situations Like This】 - Leaks found during airtight testing after processing, resulting in wasted processing costs - Even when changing foundries, the same shrinkage cavities remain unresolved - Parts with thick sections where internal cavities appear on the machined surface - Request to trace back the cause of defects to the design stage 【Achievement Scale】200 companies and 5,000 items over the last 5 years. More than 500 prototype and development achievements annually.
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At Karmo Casting Co., Ltd., we engage in aluminum processing, aluminum casting, and the casting of copper alloys other than aluminum. Manufacturing has continuously supported the backbone of Japanese industry. At Karmo Casting, we have maintained that spirit and pride, dedicating ourselves to pioneering initiatives in the industry since our founding. Our primary goal is to build partnerships with our customers. To achieve this, we believe it is essential to flexibly adapt to changes in the times and realize all kinds of needs. Our relentless pursuit of technical expertise, responsiveness, quality, and speed reflects this attitude. While sensitively and swiftly understanding our customers' thoughts, Karmo Casting will continue to accumulate tireless efforts and changes as a manufacturing company that is chosen and needed by our customers.