Comprehensive services from trial manufacturing to mass production

We offer a system which can provide everything from trial production to mass production of products by maintaining a self-hardening (hand casting) trial production factory to mass production lines with automatic casting machines

Both cast iron and aluminum handled at a single factory

Melting both cast iron and aluminum allows for trial production of both in a single mold, and also makes it possible to use compound cast iron and aluminum technologies (cast-in inserts)

Process up to product supply

SHINKOH METAL's
5 strengths

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Trial production systems capable of meeting extremely tight deadlines

Our self-hardening line has a proven track record of experience and results in production of a wide variety of quick turnaround, high difficulty cast components, particularly in trial manufacturing of aluminum castings for automotive parts. In addition to producing molds at our in-house factorys, we also increasingly handle direct fabrication of sand molds (casting molds) from 3D CAD data, allowing for even faster turnaround times.

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Turnaround time standards
Turnaround time standards
3D printer production
of sand molds
(casting molds)
We can produce cast products in as little as 10 days if 3D CAD data is available. This is the optimum method for cases where procurement deadline is the priority, or when producing only 1 cast product with no die.

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Optimal casting plan design using simulation technologies

Controlling blowholes which occur inside castings is a major issue for the casting process. The introduction of casting fluidity simulations allows for the prediction of where blowholes will occur (defect occurrence locations), which makes it possible to design optimal casting plans.

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Fluidity simulation
Fluidity simulation
Setting simulation
Setting simulation

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Inspection and quality assurance systems backed by abundant experience in the trial production business

In order to establish a satisfactory quality assurance system, we employ not only inspection equipment within our factorys, but also utilize inspection equipment at group companies and affiliate manufacturers based on customer requirements.

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Color checking
Hardness testing

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Low pressure die casting method which can minimize aluminum defects

Low pressure die casting is a casting method which differs from conventional casting methods where molten metal is poured from above, by instead filling the molten metal from below to minimize the introduction of any air pockets or inclusion, which in turn greatly reduces defects. The low pressure die casting method is well suited to an effective for casting of products such as complex shape products in which it is difficult to prevent blowhole formation, and products with high processing loss from blowholes.

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Conventional method: Sand mold gravity casting

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Cast-in joining technologies for ferrous and aluminum metals

One of SHINKOH METAL's major strengths is that we have our own cast iron and aluminum casting factory which is also capable of "cast-in" technologies where ferrous metals (cast iron, stainless steel, etc.) are cast inside of aluminum castings. As industrial machine parts have continued to become more compact and more advanced in recent years, there has also been an increase in cast-in technology needs.

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A stainless steel cooling pipe is cast-in inside of an aluminum casting
  • Technology overview

    Aluminum/ferrous metal mixed castings require review of design and forms for cast-in part core prints. In addition, as there will be no adhesion between the differing materials, it is also important to maintain control in order to prevent any gaps from occurring.

  • Value provided by technology

    Casting-in of pipes provides the component with its own cooling feature, which both improves cooling performance and also saves space.

Factory overview

Cast iron factory
  • Production capacity: 250 t/month
  • Frame size: 500×600×200/200(㎜)
  • Casting materials: FC200-250,FCD400-700
[ Equipment list ]
Equipment name Manufacturer name Model No. of units
Melting equipment 1 t/H high frequency induction furnace Kitashiba Electric 1×900kw-500Hz 2
SVC devices SHINKOH METAL 1
Molding equipment Horizontal parting flaskless molding machine Sinto Kogio FBOX-IIIR7 1
Fully automated molding line Tokyu AMFII-06L 1
Automatic converting mold robot Yaskawa Electric MOTOMAN-ES165D 1
Cooling equipment Drum cooler Nihon Asahi Kiko 1
Oscillating conveyor OMCO SYD-6D-6970 1
Sand processing Automated sand processing system OMCO 1
Sand water mixer Kurita Inc. 1
Sand cooler Sinto Kogio RCT20 1
Finishing Tumbling shot blast Sinto Kogio SNB50Y 2
Sinto Kogio SNB30Y 1
Deburring robot system Yaskawa Electric MOTOMAN-ES165D 1
Small Barinder Koyama X6-FDS12R-331GR 1
Large Barinder Koyama AGN6-FD7R-5SGR-C 1
Machining equipment Vertical NC lathe Fuji Machine Mfg. VN-31 2
Okuma ACT-V2R 1
Okuma 2SP-V3 1
Okuma 2SP-V35 1
O-M Ltd. VL-4N 1
Welding robot Nachi Fujikoshi MV16-R01-AXCML1 1
Environmental equipment 330m3/min dry dust collector Tokyu Model DDJ-12-WR 1
280m3/min dry dust collector Sinto Kogio UDC-89PS(35) 1
250m3/min dry dust collector Nippon Metal Model AJD16×3 1
Horkos JL1032-AF 1
Amano PiA-250 1
100m3/min dry dust collector Sinto Kogio FXII-110PB 1
60m3/min dry dust collector DCE DLM-V45/15-F-S 2
Nippon Metal Model AJ9×2 1
Aluminum factory
  • Production capacity: 10t/month
  • Max workpiece size: 1,000×1,000×1,000(㎜)
  • Casting materials: FC200-250,FCD400-700,ACAC2A/2B,AC4A/4B/4C/4CH,AC7A,NH42,Aluminum, Die-cast materials
[ Equipment list ]
Equipment name Manufacturer name Model No. of units
Melting equipment Melting furnace (340kg) Alca Engineering Regenerative gas burner 1
Melting furnace (130kg) Sanken Sangyo 1
Degassing system Foseco Japan GBF-FHM 1
Gravity casting machine Ishida Machine 700×400 1
Low pressure sand casting machine Shinwa Factory Holding furnace 140kg 1
Molding equipment Mold machine OMCO Self-hardening mold machine 1
Mold inverter Futaba Mfg. Model FS-TK 2
Finishing equipment Table shot blasting machine Daichu FL-115L 1
Belt grinding machine Matsuda Seiki SBA-1 1
Band saw machine Ryobi BS-110-5AS 1
TiG welder Daihen DA-300P 1
Environmental 150m3/min dry dust collector OMCO CH-42 1
65m3/min explosion proof dust collector Amano BV-2036 1
50m3/min explosion proof dust collector PI-75D 1

Testing equipment / other

[ Equipment list ]
Equipment name Manufacturer name Model No. of units
Testing equipment Fluorescent flaw detector 1
Ultrasonic wave thickness gauge TMI Dakota MX-3 1
Industrial endoscope RF Co. VZ wired 1
Vacuum type optical emission spectrometer (QV) Shimadzu Corporation PDA5520Ⅱ 1
Universal tester Shimadzu Corporation UH-30B 1
Brinell hardness tester Shimadzu Corporation HB 1
Optical metallograph Union Tokyo MC85143 1
Image analysis equipment Nishimura Graphite 1
CE meter Nakayama 1
Ultrasonic flaw detector Mitsubishi Electric UI-23 1
Digital green sand properties automatic measurement system Sinto Kogio DST-Ⅱ 1
Surface roughness measurement instrument Mitutoyo SJ-210 1
Machining center Okuma MD-56VA 1
Molds Layout machine Tokyo Boeki Techno-System Laymatic PROⅡ 1
Lathe 2
Machining equipment Milling machine 1
Band saw 1
3D-CAD/CAM System Creo,MasterCAM 3
Other Casting analysis simulator JSCAST 1
Ultra-thin cast iron plate heat treatment furnace Hiroshima Dennetsu 1
Air compressor with inverter 55 kw Mitsui Seiki Kogyo ZV55AS3i-R 1
Air compressor 55 kw Mitsui Seiki Kogyo Z556AS-R 1

CONTACT

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