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Paying exceptional attention to all processes
The quality of the product can only be achieved through fine and detailed work. This is a fact common to all products from general cast products to tee casting and direct casting, which were realized by making full use of the latest technologies. Naturally, it is essential to build a structure where equipment and instruments can be introduced in order to achieve high quality, and implement maintenance so that the best performance is demonstrated at all times in every possible work process. However, we believe that this alone is not completely sufficient. The quality of Tokorozawa Alloy Foundry has only been maintained by the high skill of every engineer related to all work processes, from the data processing of engineering drawings to the completion of the final inspection.
Fine and detailed work processes which realize high quality
1. Data Processing
Based on the engineering drawings provided by customers, we perform data processing so that castings of the highest quality can be performed. The completion of sufficiently examined designs is the first step in satisfying the requirements of the customer. This technique can be achieved with the know-how produced from abundant experience and ideas, not only relying on state of the art computers.
2. Wooden Mold Production
Completed designs are used to create wooden molds, by state of the art 3D machining and the hands of experienced craftsmen. Needless to say, the level of detail of the wooden molds which greatly influences the completeness of the product will not be produced without the knowledge of the craftsmen who understand the main technical points in the subsequent production of the sand mold and casting process. This is an important process which greatly influences the quality of the finished product.
3. Sand Mold Production
Sand molds are produced using a high quality casting sand which is suited to the process. The sand mold is completed after each mold is carefully inspected for both hand molding and machine molding defects/errors. The completed sand mold is carefully assembled in preparation for the molten bath.
4. Molten Bath
A molten bath adjusted to the alloy, which meets the conditions required when completed as a product, is poured into the sand mold. The temperature of the molten bath is finely adjusted according to the type of alloy and the shape of the sand mold. It is then poured is poured into the mold at an appropriate speed using a gravity die casting process, or a low pressure die casting process.
After the molten bath alloy in the sand mold hardens sufficiently, the sand mold is broken down and the product is removed. Although this seems to be simple work, it is necessary to pay careful attention so that the product is not damaged. The remaining casting sand is then carefully removed in the complicated molded portions.
The portions not required for the product, such as the burrs, which occur during the assembly of the sand mold, and risers are removed. Since all the finishing to meet the dimensions on the engineering drawing is performed by the hands of experienced employees, the inspection of products can also be performed at the same time.
7. Heat Treatment
Heat treatment is performed on the products which have surface hardness instructions, in order to acquire the necessary hardness. Since heat treatment is performed by calculating the temperature, time, etc. based on the shape and capacity of the product using a fully automated dedicated furnace, an ideal surface hardness can be acquired reliably.
Coating is generally performed for the purpose of decoration, protection or rust protection of the product. Tokorozawa Alloy Foundry mainly uses a "spray coating" (a coating which is sprayed in a mist with high pressure air) and a "baking coating" (a spray coating which is generally sprayed for 30 minutes or more at a temperature of 120 to 200 ºC).
9. Material Inspection
Material inspections are performed in this stage, regardless of the use of heat treatment. A fiberscope is used for the portions which are not visible from the front side of the product. A color check is also performed at the same time, to prevent the overlooking of cracks in micro units generated in the product.
10. Precision Machine Processing
Regarding products which require precision processing accuracy, we perform precision machine processing using CNC and other milling machines. We have established a structure which makes it possible for us to handle orders with extremely high precision dimensions, such as sliding parts in engines.
11. Final Inspection
Products which have completed all the processes go through a final inspection by dedicated inspectors, using a 3 dimensional coordinate measuring machine. Only products which pass this extremely strict inspection process are allowed to be shipped to customers as a quality product of Tokorozawa Alloy Foundry.