Proposal for cost reduction in aluminum sand casting from machining.
AC4CH/AC4C/AC4B/AC4A/AC2A and other 10 aluminum alloys (sand casting of machined products)
More than half of the block material becomes chips, increasing material costs and processing time. By switching to sand casting, costs can be reduced with more than five pieces, and ±0.03mm can be achieved with 15 units of 5-axis machining centers.
The parts are machined from block material, with most of the material turning into chips. There are many pockets and cutouts, and processing one piece can take several hours. As the quantity increases, the material costs and machine operating time become burdensome. Are there any such parts? While machining does not require molds and can be produced quickly, it involves shaping larger materials than the final form, which means that as the complexity of the shape increases, the amount of material removed and the time taken also increase. For parts that are produced in larger quantities, this difference directly translates into cost differences. Karmo Casting proposes sand casting shapes that can be cast close to the final form based on the drawings of machined parts. By designing and manufacturing wooden molds in-house and creating castings that minimize the machining allowance to necessary areas, we reduce the amount of material removed and the processes involved. After casting, we finish multiple surfaces using a 5-axis machining center and verify dimensions with a three-dimensional measuring machine before shipping. The interface for molds, casting, and machining is handled by a single company, allowing for a shape to be confirmed with one prototype before switching. We are offering a free collection of VA/VE case studies, including examples of cost reduction by switching from machining to casting. Please download it from the link below.
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basic information
【Scope of Commission】Integrated production of wooden pattern making / casting / machining / inspection (including design for casting of machined parts) 【Conversion Guidelines】Cost reduction for conversion from machining starts at 5 or more pieces 【Lot Size】From 1 piece (switching after confirming shape in prototype) 【Casting Size】50mm square to 1,000mm square / Minimum thickness 1mm (local) / 1.5mm (overall) 【Supported Materials】 - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 - Processing Only: SCS13 / FCD450 / A5052 【Casting Processes】In-house capabilities for five methods: sand casting / self-hardening / alkaline phenolic / cold box / metal mold 【Machining Equipment】15 units of 5-axis machining centers (6 with pallet changers) / 2 gantry machines / 3 vertical machines / 2 NC lathes 【Machining Accuracy】Geometric tolerance ±0.03mm 【Inspection Equipment】2 contact-type 3D measuring machines / non-contact 3D digitizer (deviation 30-80μm) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you could provide the current drawings of the machined products and the annual required quantity, we will offer a free estimate along with a proposed shape for casting. The conversion from machining is cost-effective for quantities of five or more. Since we produce the wooden molds in-house, there are no outsourcing costs for the molds. We will also present a comparison between machining and casting.
Price range
P2
Delivery Time
※Prototype shipping takes a minimum of 2 weeks, and the initial production including mold making takes a minimum of 3 weeks. Since this may vary depending on the shape, quantity, and processing locations, please let us know your desired timing and quantity for the switch.
Applications/Examples of results
【Applicable Industries】Industrial Machinery / Machine Tools / Semiconductor Manufacturing Equipment / Robotics / Agricultural Machinery / Communication Equipment / Ships / Railways / Automotive & CASE / Power & Energy 【Achievements】 ■ Motor housing for automotive EVs (AC4B-T6) ■ Base and pedestal for semiconductor manufacturing equipment (AC4CH) ■ Aluminum parts for agricultural machinery (AC4A-T6 / high precision finishing) ■ Industrial machinery parts (AC4CH-T6 / complex shapes with 11 cores) 【Used in Such Situations】 - Parts with many pockets and cutouts, where most of the block material becomes chips - Long processing time per unit, with machining centers fully occupied - Annual required quantity exceeds 5 units, and a review of whether to continue with machining is desired - Procurement of large block materials takes time, making delivery dates unpredictable 【Achievement Scale】200 companies and 5,000 items in the last 5 years. Over 500 prototypes and development achievements annually.
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Company information
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.
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