Complex internal passages - High difficulty aluminum casting case
A body with built-in waterways and strict machining tolerances. Our company's top-level high-difficulty castings are produced consistently from core manufacturing to machining with 15 units of 5-axis machining centers, with geometric tolerances of ±0.03mm.
I want to create water channels inside the body. However, the shape of the core is complex, and there are concerns about the flow of molten metal. Additionally, the processing tolerances are strict, making it inherently a difficult product, and even when searching separately for casting and machining, it is hard to find someone willing to take on the job. Are you facing issues with such components? Castings that incorporate water channels are challenging because the production of cores that shape narrow, curved passages is difficult, and measures to ensure the flow of molten metal reaches even the thin parts during casting are essential. Furthermore, to achieve strict tolerances, precision management that considers machining standards from the casting stage is necessary. When casting and machining are separated, this management can be interrupted between processes. Karmo Casting is a foundry manufacturer that handles everything in-house, from the design and production of wooden patterns and cores to casting, machining, and inspection. We confirm the flow of molten metal and solidification in advance through casting simulations, finalize multiple surfaces with a 5-axis machining center, and verify dimensions with a three-dimensional measuring machine before shipping. This product, which has become one of the most challenging for us, was managed for precision consistently from casting to machining. We are offering a free guidebook on casting defect countermeasures and a collection of VA/VE case studies. Please download them from the link below.
basic information
【Scope of Contract】 Production of wooden patterns and cores / Design of plans / Casting / Machining / Integrated production of inspection 【Supported Shapes】 Complex shapes requiring internal waterways and passages within the body 【Quality Measures】 Pre-confirmation of flow and solidification through casting simulation (countermeasures for poor flow) 【Supported Lot Sizes】 From 1 piece 【Casting Sizes】 50mm square to 1,000mm square / Minimum thickness of 1mm (local) and 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 capabilities for five methods: sand casting / self-hardening / alkaline phenolic / cold box / metal mold 【Machining Equipment】 15 units of 5-axis machining centers (6 with pallet changers) / 2 gantry 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 provide us with the drawings (showing the waterway shape and processing tolerances), we will offer a free estimate that includes consideration of the core composition and casting plan. By handling both casting and processing together, we can reduce the hassle of having separate ordering sources. You can verify the shape and accuracy with prototypes starting from one piece, and a factory tour before finalizing the contract is also possible.
Delivery Time
The prototype will be shipped in a minimum of 2 weeks, and the initial production, which includes the creation of the wooden mold, will take at least 3 weeks. The timeline may vary depending on the complexity of the core structure, shape, and processing areas, so please let us know your desired delivery date.
Model number/Brand name
AC4CH/AC4C/AC4B/AC4A/AC2A and other 10 aluminum alloys (water channel embedded, high difficulty castings)
Applications/Examples of results
【Industries Served】Industrial machinery / Machine tools / Semiconductor manufacturing equipment / Power and energy / Railways / Ships / Robots / Automotive and CASE / Aerospace 【High-Difficulty Cases】 ■ Aluminum castings with waterway shapes in the body (achieved through integrated management of casting to machining with complex core production and measures against poor flow) 【Other Complex Shape Achievements】 ■ Industrial machine parts (AC4CH-T6 / complex shapes with 11 cores) ■ Cylinder cases for railway vehicles (AC4CH-T6 / complex shapes with 6 cores) ■ Copper alloy castings for power equipment (CAC406 / thin-walled, internal passages, measures against uneven thickness) 【Used in Such Situations】 - Want to create housings or bodies with built-in cooling waterways as a single casting - The core is complex, and other companies have declined to cast it - Want to consult from the design stage for shapes that include thin-walled sections prone to poor flow - The accuracy of the casting affects machining tolerances, and want to consolidate casting and machining with one company 【Achievement Scale】In the last 5 years, 200 companies and 5,000 items. 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.