Iron Casting and Machining Process

After 20 years development, we have below casting and maching Equipment to supply different parts:

Product Specifications & Capacity:Product Size Range: 100mm – 1800mm

Product Weight Range: 1kg – 1500kg

Annual Production Capacity: 30,000 tons

Foundry Production Equipment:

Equipment	Quantity	Specification
Sinto Automatic Molding Lines (Japan)	2 units	600mm × 800mm
Iron Mold Sand-Coated Lines	2 units	1200mm × 1000mm
Resin Sand Production Lines	2 sets	–
Sand Core Making Equipment	12 sets	–
Melting Furnaces	12 units	2-ton capacity: 4 units 0.75-ton capacity: 8 units
Sand Treatment Lines	2 sets	–

Primary Machining Equipment:

Equipment (English / Chinese)	Quantity	Specification / Travel	Brand / Origin
Horizontal Lathe / 卧式车床	20 units	Travel: 100mm – 600mm	Domestic (China), Baoji
Vertical Lathe / 立式车床	30 units	Travel: 250mm – 1000mm	You Ji (Taiwan, China)
Vertical Machining Center (VMC) / 立式加工中心	80 units	Travel: 1060mm – 1800mm	Tongtai (Taiwan, China)
Horizontal Machining Center (HMC) / 卧式加工中心	20 units	Travel: 630mm – 2000mm	Doosan (Korea), Makino (Japan), Okuma (Japan)
Gear Hobbing Machine / 滚齿机	5 units	Max. Module: 6	Domestic (China), Chongqing
Gear Broaching Machine / 拉齿机	2 units	40-ton Pulling Force	Domestic (China)

Foundry Process Flow Steps

The casting process involves multiple steps, especially when customizing components for specific industries. The workflow is as follows:

1.Review the customer’s 2D drawings and 3D CAD models of the part.
2.Create a 3D model of the part and confirm the prototype with the customer.
3.Produce reusable sand cores and metal molds.
4.Complete the Production Part Approval Process (PPAP).
5.Melt cast iron raw materials and alloys, then pour them into automated molding sand molds.
6.Allow the castings to cool and solidify, followed by gating system removal (manual and automated grinding).
7.Shot blasting to remove contaminants and smooth rough surfaces.
8.Surface treatments such as painting, electrophoresis, or powder coating.
9.Finish the components through CNC machining.

STEP 1

Feasibility Analysis with the Customer

We request potential customers to provide 2D drawings and 3D CAD models for technical review. If additional machining is required for the casting, we also need the corresponding machining design drawings.
This technical review procedure aims to confirm the castability of the target component and ensure that the final casting meets all of the customer’s technical requirements.

STEP 2

Pattern Making

After designing the mold, mold flow analysis is conducted to verify the process for customer confirmation.

STEP 3

Mold Manufacturing

Once the customer has finalized and approved the model, mold manufacturing begins.
Reusable metal molds and sand cores are produced.
Cores are typically placed inside the mold to form required holes and cavities. For this purpose, sand mixed with thermosetting resin is used to create the cores.

STEP 4

Production part approval process (PPAP)

A small batch of samples is cast using the manufactured metal molds and submitted to the customer for approval along with the PPAP documentation. Upon receiving the customer’s PWS (Part Work Submission Approval), the mold is ready for mass production.

STEP 5

Mass Production: Molten Iron Melting and Automated Pouring Process

The metal is melted and then poured into the sand molds using automated equipment.

STEP 6

Gating System Removal

After the casting solidifies and cools, risers are removed using hydraulic shears.

STEP 7

Shot Blasting

This step is used to smooth rough surfaces and remove surface contaminants.

STEP 8

Surface Treatment

Surface treatments such as painting, electrophoresis, or powder coating are applied as per customer requirements.

STEP 9

CNC Machining

The final step involves finishing the cast part through CNC milling and precision CNC turning to meet the customer’s design specifications. CNC milling cuts the part from different angles to shape it as required. CNC turning is used for drilling, grooving, and reaming; it forms the inner and outer surfaces of cylindrical, conical, and curved components.