Proposal case for cost reduction in copper alloy sand casting from machining.
Aren't you machining expensive copper alloy round bars and plates until most of it becomes chips? By switching to sand casting, you can reduce costs with five or more pieces, compatible with CAC8 material types.
We are machining parts made of bronze, brass, and aluminum bronze from round bars and thick plates. Every time we arrange materials, we are concerned about the high unit price, and much of what we cut ends up as chips. The ratio of waste increases with hollow sections and shapes with steps. Copper alloys are inherently expensive compared to aluminum and iron, so the amount removed from the material directly reflects the cost. In machining, where we prepare a material that is larger than the finished shape, more complex parts result in a greater amount of purchased material being wasted. Karmo Casting proposes shapes for sand castings that are close to the finished form based on the drawings of the machined parts. By designing and manufacturing wooden patterns in-house, we can shape hollow sections and steps in advance with castings, thereby reducing the necessary material and the amount to be machined. We accommodate eight material types, including bronze such as CAC403 and CAC406, high-strength brass, and aluminum bronze. Machining and inspection using a three-dimensional measuring machine are also conducted in-house, allowing us to verify the shape with a single prototype before switching. We are offering a free collection of VA/VE case studies, including examples of cost reduction by switching from machining to casting. Please download it from the link below.
basic information
【Scope of Contract】Integrated production of wooden mold making / casting / machining / inspection (including design for casting of machined parts) 【Conversion Guidelines】Cost reduction when converting from cutting processing for 5 or more pieces 【Lot Size】From 1 piece (switching after confirming shape in prototype) 【Supported Materials】 - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B 【Casting Size】From 50mm x 50mm to 1,000mm x 1,000mm / Minimum thickness of 1mm (local) and 1.5mm (overall) 【Casting Processes】In-house capabilities for five methods: sand mold / self-hardening / alkaline phenolic / cold box / metal mold 【Machining Equipment】15 units of 5-axis machining centers / 2 gantry type / 3 vertical type / 2 NC lathes 【Machining Accuracy】Geometric tolerance ±0.03mm 【Inspection Equipment】2 contact-type 3D measuring machines / non-contact 3D digitizer (deviation 30-80μm) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you could provide the drawings and materials for the machined products, as well as the annual required quantity, we will provide a free estimate along with a proposed shape for casting. The transition from machining is cost-effective for quantities of five or more. The higher the unit price of the copper alloy, the more significant the savings from material reduction. Since the wooden molds are made in-house, there are no outsourcing costs for the molds.
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Model number/Brand name
CAC403, CAC406, etc.
Applications/Examples of results
【Industries Served】Power and Energy / Marine / Industrial Machinery / Machine Tools / Railways / Semiconductor Manufacturing Equipment / Communication Equipment 【Achievements】 ■ Copper alloy castings for power equipment (CAC406 / thin-walled, internal passage, and uneven thickness measures) ■ Copper alloy castings for marine applications (from wooden patterns to pressure testing) ■ Copper alloy castings for industrial machinery (comprehensive support from wooden pattern design) 【Applications】 - Machining hollow bushes and sleeves from bronze round bars - Machining complex parts from thick plates of aluminum bronze and high-strength brass - Reviewing whether to continue machining due to rising material costs of copper alloys - Wanting to compare costs when casting, as the annual requirement exceeds 5 units 【Scale of Achievements】200 companies and 5,000 items in the last 5 years. Over 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.