TSUBAKIMOTO IRON CASTING　CO. Product Lineup

In a foundry, each has its own preferred product sizes. We believe that "big does not always accommodate small." For example, when producing small castings on a manufacturing line designed for heavy items, managing and handling products within the process can become difficult, potentially affecting work efficiency and quality control. Additionally, using molten metal transport equipment intended for large products can lead to excess molten metal when dealing with small castings, which may result in lower yield rates. Furthermore, processes such as deburring, finishing, and inspection require equipment and methods suitable for the product size. Therefore, the compatibility of the production line in a foundry with the sizes of products being handled is crucial. Our company specializes in small castings. We optimize all processes, from melting and pouring to molding, mold breaking, deburring, and inspection, for small castings. As a result, we can achieve stable quality and high productivity, offering cost-competitive products. If you are looking for a supplier of small castings or have concerns regarding quality or cost, please feel free to contact us.

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Since its establishment, Tsubakimoto Foundry has aimed for "trusted casting production," supplying ultra-small castings to various industrial sectors, including the automotive industry. "High Mini Casting" is our technological development theme that represents "high-quality materials, high precision, and ultra-small castings." Specifically, our fundamental principles include providing "suitable high-quality materials that meet needs," "high dimensional accuracy with minimal machining," and "ultra-small castings weighing 500g or less." By enhancing the technology of High Mini Casting, we aim for speedy and accurate responses to the demands of the times and our customers' requests. 【Fundamental Principles】 ■ High-Quality Materials - Suitable high-quality materials (such as FC, FCD) that improve machinability and contribute to cost reduction. ■ Ultra-Small Castings - Ultra-small castings weighing 500g or less, with an average weight of 300g. ■ High Precision - Minimal machining due to high dimensional accuracy (near-net shape). *For more details, please refer to the PDF materials or feel free to contact us.

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We handle products that improve the machinability of cast iron FC. We can provide raw materials. Please check the attached catalog and contact Tsubakimoto Casting/Kataoka or Ikoma. Materials: FC200, FC250, FC300

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Is there any problem with the appearance of the castings? A beautiful casting surface is linked to quality. Our company thoroughly manages the sand. In the sand mixing process, we perform "double mixing," where we first do a preliminary mixing, store it for a while to "rest," and then proceed with the main mixing. This stabilizes the sand and makes it easier to prepare for mold making. There are not many examples of double mixing in foundries due to equipment introduction and cost considerations. Benefits of stable sand: - The casting surface has fewer irregularities and is beautiful. - There is less variation in dimensions. (This also leads to near-net shape and cost reduction.) - The filling of the molds is better, and there is less sand sticking. (This also reduces chipping of cutting tools.) Stabilizing the sand (reducing variation) is an important factor in preventing defects. Thank you very much.

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A Suitable Option for Mass Production: Small Castings When selecting the manufacturing method for small parts, it is not uncommon to struggle with the decision of whether to use casting or forging. The optimal method varies depending on the required performance, cost, and shape. Cast iron castings are characterized by good machinability, excellent vibration absorption, corrosion resistance, and wear resistance. Additionally, they can be formed into complex shapes in a single process, contributing to a reduction in the number of parts and processing steps. Our sand casting process is flexible enough to accommodate everything from small batches to mass production. In particular, for mass production of small cast iron parts, we can achieve high cost performance with large-scale production using a single model (master mold). Furthermore, before mold production, we conduct flow and solidification simulations to reduce the risk of casting defects and improve initial quality. Leveraging the quality control techniques developed in automotive parts, we provide cast iron products with stable quality. If you are struggling with the choice between casting and forging, please feel free to consult us.

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We have received high praise for our automotive castings and industrial machinery castings. We have gained trust in mass production of ultra-small castings weighing less than 500g, and we will continue to provide products that meet the increasingly diverse needs in the future. 【Product Items】 ■ Gray cast iron products FC200–FC300 ■ Ductile cast iron products FCD450–FCD700 ■ CV cast iron products FCV350–FCV450 ■ Alloy cast iron products Chromoly *For more details, please contact us or download the PDF to view.

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Vertical Split Blow Squeeze Molding that Balances Mass Production and Quality Our company has introduced vertical split blow squeeze molding machines (vertical molding machines) for the production of small castings. This molding method excels in mass production as it allows for continuous production of molds, contributing to improved production efficiency. Furthermore, the blow squeeze method enables the high-density and uniform filling of molding sand, resulting in minimal dimensional variation and stable quality. We cater to a wide range of projects from small lots to mass production. If you are considering small cast iron castings, please feel free to contact us.

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What is an air conditioning compressor? The air conditioning compressor is an essential component that supports the heating and cooling functions of an air conditioner. The compressor compresses the refrigerant gas and circulates it, expelling heat from indoors to outdoors and bringing outdoor heat indoors. If this cycle does not function properly, the air conditioner cannot regulate the temperature effectively. Applications of the inclined plate compressor The primary application of the inclined plate compressor is in car air conditioning, but it is also used in a wide range of air conditioning systems beyond just vehicles. The cast material used for the inclined plate compressor components is "spheroidal graphite cast iron (ductile cast iron; FCD)," which is a type of cast iron known for its excellent strength and toughness.

• air conditioning
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What is an air conditioning compressor? The air conditioning compressor is an essential component that supports the heating and cooling functions of an air conditioner. The compressor compresses the refrigerant gas and circulates it, expelling heat from indoors to outdoors and bringing outside heat indoors. If this cycle does not operate correctly, the air conditioner cannot regulate the temperature properly. What is a balance weight in an air conditioning compressor? The balance weight is a component used inside the compressor, designed to reduce and offset vibrations and unbalanced forces that occur during operation. When the compressor operates, it is prone to uneven inertial forces, which can cause vibrations and noise. The balance weight corrects these imbalances, ensuring stable operation and improving reliability of the compressor. The quality of the casting and dimensional accuracy are essential. The FCD used for the balance weight in our company refers to "spheroidal graphite cast iron (ductile cast iron)," which is a type of cast iron known for its excellent strength and toughness.

• air conditioning
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Engines are used in various applications such as automobiles, trucks, buses, ships, airplanes, railways, and generators. We have small cast iron parts for our engines, including components for timing drives. Timing drive components refer to the group of parts that control the opening and closing timing of the engine's intake and exhaust valves. Types include: - Tensioners for timing chains, camshafts, balancer shafts, and many others. The selection of cast iron materials is based on the application: - FC, FCD, and others. For more details, please download the materials. Thank you very much.

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Are you having any issues with the post-processing of cast materials? Our company is a casting manufacturer that handles everything from the production of main molds to the material for products. Through our network of partner companies, we also offer services such as machining, plating (electro-galvanizing, etc.), painting (cationic electrodeposition coating, etc.), and heat treatment (annealing, etc.). We will solve any problems you have with cast iron products. Thank you for your consideration. *You can download our company brochure.

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Common issues with small castings include: When producing castings, smaller sizes are more susceptible to the effects of molten metal temperature and mold (sand). Specifically, problems arise such as rapid solidification, poor flow of molten metal, and the tendency for casting defects. Additionally, defects are more noticeable in smaller items, and the demands for appearance quality are strict, necessitating 100% inspection. Our company specializes in small cast iron castings. We address these issues through our accumulated know-how, thorough sand management, molten metal management, quality inspection, and the use of solidification simulations. Please feel free to contact us. *You can download our company brochure in PDF format. We can accommodate lot sizes from 100 to over 10,000. (We produce 1.5 million units monthly, primarily focusing on automotive and industrial parts.)

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Our company has been producing castings for mass-produced automotive parts, such as timing drive components for automotive engines and compressor parts for car air conditioning systems, which require strict quality standards for many years. Leveraging the quality management know-how cultivated in the automotive industry, we now provide high-quality casting materials for general industrial machine parts, pump parts, construction and civil engineering-related parts, and industrial equipment parts. Our strength lies in the stable quality and mass production capabilities that can only be achieved by a specialized small casting manufacturer. Material Management The quality of castings is greatly influenced by the material. We implement consistent material management from molten metal management to shipment, focusing on FC and FCD materials. Dimensional Management In mass-produced castings, controlling dimensional variation is crucial. Traceability Management We have established a system to clearly manage manufacturing history, allowing for the rapid identification of affected lots in the event of quality anomalies. Mass Production Quality Assurance We produce mass quantities of small castings, reaching hundreds of thousands per month, and carry out continuous quality maintenance activities required in the automotive industry. For small mass-produced castings, you can rely on us. We provide quality assurance by leveraging the rigorous quality management system developed through our experience in automotive parts.

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Our company produces small castings not only for automobiles but also for construction and civil engineering. For example, in construction and civil engineering small castings, we manufacture hinge fittings that connect manhole covers and frames, wire clips, and other connecting hardware. These require safety and strength. Our company conducts thorough management through a material management system developed from our experience with automotive castings. Please feel free to contact us. (We can manufacture small sizes.) ------------------------------------------------------------------------------------------------ Material FC (General Characteristics) Vibration absorption, wear resistance, high compressive strength, good machinability, low cost. Characteristics of Material FCD (General Characteristics) High strength (strength similar to steel), toughness (resistant to cracking), wear resistance, good machinability, low cost (more expensive than FC).

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Our small castings are produced not only for automobiles but also for general-purpose items and castings for restaurants. For general-purpose items such as iron plates and grates, as well as castings for food use (for restaurants), high-strength, heat-retaining, and durable cast iron (FC/FCD) is utilized. Features of cast iron castings (for food use, such as iron plates and grates): - It is possible to manufacture products with a design aesthetic. - They are durable and resistant to breakage, ensuring longevity. - They have excellent heat retention, making it difficult for food to cool down. - When heated, they emit far infrared rays, allowing for crispy exteriors and juicy interiors when grilling meat, for example. - Oil adheres easily (the surface texture of cast iron allows oil to penetrate, making it less likely for food to stick). - They can supplement iron intake, contributing to health. Thank you very much.

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Our company has adopted an automatic pouring machine. By implementing the automatic pouring machine, we achieve stability in quality, improved productivity, and enhanced safety (improvement of the working environment). Stability in quality leads to a reduction in defects such as casting defects and shape irregularities by minimizing variations in pouring volume and speed. Improved productivity is also achieved by reducing variations in pouring volume and defects. Enhanced safety protects workers and mitigates the risk of production stoppages (inability to ship). Thank you very much.

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We adopt a melting process that pursues stable material quality using a high-frequency induction furnace (melting furnace). The image shows the pouring process from a high-frequency induction furnace (melting furnace) for cast iron castings. Our melting process utilizes a high-frequency induction furnace (electric furnace), allowing for component management and temperature control. We conduct thorough material management to provide high-quality materials. We respond to our customers' needs. Types: - Gray cast iron products: FC200 to FC300 - Ductile cast iron products: FCD450 to FCD700 - CV graphite cast iron products: FCV350 - Wear-resistant alloy cast iron: Cr-Mo (chromoly) cast iron

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Design of cast products capable of complex shapes - Small cast iron items Main features of cast products: 1. Complex shapes can be formed as a single piece (such as ribbed structures without welding, hollow shapes, and curved shapes). 2. A wide range of material options (such as FC and FCD). 3. Good yield (reducing the amount of machining required). 4. Lower mold costs (the main mold for casting can be repeatedly produced using sand molds). However, while it seems possible to design freely, if the overall balance is not maintained in terms of shape and thickness, it can lead to difficulties in machining or cause casting defects in thicker areas. Some issues can be resolved through mold design (casting plans), but consulting with our company during the design phase can facilitate a smoother initial product launch. We will solve your problems with cast iron products. Please feel free to contact us. *Company brochure available for download.

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We have received high praise for our automotive castings and industrial machinery castings. We have gained trust in mass production of ultra-small castings weighing less than 500g, and we will continue to provide products that meet the increasingly diverse needs in the future. 【Product Items】 ■ Gray cast iron products FC200–FC300 ■ Ductile cast iron products FCD450–FCD700 ■ CV cast iron products FCV350–FCV450 ■ Alloy cast iron products Chromoly *For more details, please contact us or download the PDF for more information.

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