Aluminum machining | Machining A5052 from one piece with a tolerance of ±0.03
Machining with many surfaces and pockets is often disliked by processing companies when done in small quantities. By minimizing setup with 15 units of 5-axis machining centers, A5052 can be processed with a tolerance of ±0.03mm from a single piece.
I want to machine brackets, jigs, and covers for devices from A5052 sheet material. However, due to the high number of surfaces, pockets, and holes, processing companies tend to be reluctant to take on small quantities. This is a common concern expressed by design and procurement personnel from equipment manufacturers. The labor-intensive aspect of multi-surface machining is the setup change required every time the orientation of the cutting tool is altered. In a 3-axis machine, it is necessary to change the setup for each surface, which increases both the time required and the variability in precision due to the need to re-establish reference points each time. Karmo Casting owns 15 five-axis machining centers, six of which are equipped with pallet changers. This allows us to reduce the number of workpiece changes and process multiple surfaces, thereby minimizing the setup burden even for small quantities, while achieving a geometric tolerance of ±0.03mm. Inspections are conducted using a three-dimensional measuring machine. If the volume increases and casting becomes more advantageous, we can also propose a transition to casting. By performing both machining and inspection in one factory, we can immediately reflect the measurement results in the next machining process, thereby reducing dimensional variability even for small quantities. We are offering a free collection of VA/VE case studies that summarize examples of cost reduction, including method transitions.
basic information
【Materials for Processing】A5052 / SCS13 / FCD450 【Processing Equipment】15 units of 5-axis machining centers (6 with pallet changers) / 2 gantry machines / 3 vertical machines / 2 NC lathes 【Processing Accuracy】Geometric tolerance ±0.03mm 【Lot Size】From 1 piece (processing of supplied materials is also possible) 【Inspection Equipment】2 contact-type 3D measuring machines / non-contact 3D digitizer (deviation 30-80μm) 【Method Transition】Cost reduction for conversion from machining to casting for 5 or more pieces 【Casting Materials Supported】10 types of aluminum alloys / 8 types of copper alloys 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2 【Processing Achievements】Machined parts for semiconductor equipment and industrial machinery (from 1 piece) 【Transaction Records】5,000 items from 200 companies in the last 5 years 【Factory Tours】Possible even before contract signing
Price information
If you provide us with the drawings (along with 3D data if available) and the quantities, we will give you a free estimate. The more suitable the shape is for 5-axis machining, the easier it will be to reduce processing costs even for small quantities. If the required quantity is five or more, we will also provide the costs for replacing it with castings.
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Model number/Brand name
A5052 (machining only; supplied material acceptable) / machining of 10 types of aluminum castings
Applications/Examples of results
【Industries Served】Semiconductor manufacturing equipment / Machine tools / Robots / Industrial machinery / Aerospace / Electrical and electronic equipment 【Related Achievements】 ■ Aluminum machined parts for semiconductor devices (from 1 piece / geometric tolerance ±0.03) ■ Aluminum machined frames for industrial machinery (large / from 1 piece / ±0.03) ■ Aluminum processed products for aerospace (thin-walled small parts with a thickness of 3mm / JIS Q 9100) 【Used In Such Situations】 - Want to machine just a few brackets or covers for equipment - Parts with many surfaces and pockets, requiring multiple setups - Want to process supplied material A5052 - If the quantity increases, also want to compare switching to castings - Want to entrust everything from prototyping 1 piece to verification with three-dimensional measurement 【Achievement Scale】In the last 5 years, 200 companies and 5,000 items. More than 500 prototyping 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.