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 line to mass production lines with automatic casting machines

Both cast iron and aluminum handled at a single factory

We produce both cast iron and aluminum cast products in a single plant so we are also able to handle cast iron and aluminum bonding technologies (casting-in)

We handle all production from raw materials to machining

Our system allows us to handle everything from mold fabrication to cast iron and aluminum materials production and machining

We offer proposals for optimal production processes

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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Approximately delivery times for prototypes via 3D laminate sand mold casting
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 plants, but also utilize inspection equipment at group companies and affiliate companies based on customer requirements.

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Color checking
Hardness testing

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Cast-in joining technologies for ferrous and aluminum metals

One of our major strengths is that we have our own cast iron and aluminum casting plant 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.

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Ultra-thin-wall casting via HVC
echnologies (vacuum degassing)

Vacuum degassing (HVC) of cast iron improves molten viscosity and allows for production of ultra-thin-wall castings, while also reducing shrinkage cavities and improving yield rates.

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What is HVC (Higher Valuable Casting)?

■Our company's original casting technology which makes it possible to achieve higher quality molten metal through molten metal processing (vacuum degassing).
■Compared to standard molten metal, molten metal processed via this method can be expected to have improved fluidity, thinner walls and lighter weight, improved machinability, decreased level of defects, and higher yield rates.

Pushing the limits of thin-walled casting using our original casting technologies

1Thinner walls and lighter weight » The limit of wall thickness for conventional castings is generally considered to be approximately 4-5 mm, however by controlling the gases in molten metal, we are able to produce ultra-thin-walled castings (no-chill casting) of 1-2 mm.
2Machinability improvement » HVC processed materials increase ferritic matrix by 20-30% over normal cast iron which greatly improves machinability.
3Reduced level of defects » Promotion of ferritization can reduce shrinkage cavities, which are internal defects, which in turn reduces the level of defects.
4Improved yield rate » HVC processing allows for reduction of dead head (feeder) which can result in an improved planned yield rate of 10% or more.
HVC casting process

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 (frame) Yaskawa Electric MOTOMAN-ES165D 1
Deburring robot system (lid) Yaskawa Electric MOTOMAN-GP71 1
deburring machine for small sized castings Koyama X6-FDS12R-331GR 2
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 2
60m3/min dry dust collector DCE DLM-V45/15-F-S 2
Nippon Metal Model AJ9×2 1
Self-hardening factory
  • Production capacity: 1,200 M (molds)/month
  • Max workpiece size: 1,000 × 1,000 × 1,000(㎜)
  • Casting materials: FC200-250, FCD400-700, AC2A/2B, AC4A/4B/4C/4CH, AC7A, NH42, aluminum die casting materials
[ Equipment list ]
Equipment name Manufacturer name Model No. of units
Melting equipment Aluminum melting furnace (350 kg) Daisen Engineering SW-350 1
Aluminum melting furnace (200 kg) Daisen Engineering SW-200 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 Self-hardening sand processing equipment OMCO 1
Long arm mixer OMCO LAM-5S 1
Mold inverter Futaba Mfg. Model FS-TK 2
Finishing equipment Crane shot blasting machine Sinto Kogio KSB-10Y 1
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 equipment 150m3/min dry dust collector OMCO CH-42 1
80m3/min dry dust collector Amano PiE-125 1
65m3/min dry dust collector Sinto Kogio ES-M3G5 1
65m3/min explosion proof dust collector Amano BV-2036 1
50m3/min explosion proof dust collector PI-75D 1
Machining
plant
  • Max workpiece size: approximately 1,000 mm
[ Equipment list ]
Equipment name Manufacturer name Model No. of units
Machining equipment NC lathe Mori Seiki SL-25B5 1
Mori Seiki CL-15 1
Yamazaki Mazak QTN-200 1
General-purpose lathe DAINICHI DLG-SH63×150 1
Machining center (vertical MC) Fanuc T-MODEL10 1
Fanuc α-T10A 1
OKK PCV-40 1
Enshu 400V 1
Mitsubishi MV5CN 1
Mori Seiki MV-junior 1
Daiichi Seiki DIMAX-8 1
Okuma & Howa Machinery MILLAC-611V 1
Machining center (horizontal MC) Okuma MA600HⅡ 1
Mold fabrication / Machining equipment Machining center (portal MC) Yamazaki Mazak FJV-35/60 1
Machining center (vertical MC) Okuma MD-56VA 1

Testing equipment / other

[ Equipment list ]
Equipment name Manufacturer name Model No. of units
Testing equipment 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 testing machine Shimadzu Corporation UM-300KNX 1
Brinell hardness tester Shimadzu Corporation HB 1
Optical metallograph Union Tokyo MC85143 1
Image analysis equipment Nishimura Graphite 1
Sample grinder/polisher Struers LaboPol-20 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
Measurement equipment Layout machine Tokyo Boeki Techno-System Laymatic PROⅡ 1
Coordinate measuring machine Mitutoyo B-706 1
Machining equipment Milling machine 1
Lathe 2
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

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