Sand mould casting

Superprecision sand mould casting industrial method
(IPSC industrial method)

Feature of precise sand mold construction method

Presently, trial manufacture also reaches last stage, the prototype of high accuracy which closer to the die-cast item is required. But, many processes bet on the production, the fact that also cost is rather high is present condition.

Then, our company with the introduction of superprecision sand mould casting industrial method, from start of trial manufacture reached the point where we can actualze the offer the material which is closer to the Die-cast product.

《Feature of IPSC industrial method》

1. Precision corresponds to the general tolerance of the metal mold casting.
2. In comparison with gypsum casting, cost is the 1/3~3/4.
   (However, depend on product shape, there are some differences.)
3. The gross production quantity possible up to 400~600, depend on product shape.
4. Surface roughness as shown in the paper, is close with the die-cast product.
5. Possible to change wooden mould directly, if any design change.
6. When starting the trial manufacture, the material which closer to the die-cast product was produced.
7. The accuracy is higher than past casting product and the process was less.

Runner Equality to Die-cast Hot water flow to fillet, corner R Surface accuracy Average 25z (Max 15z) A necessary part will keep the surface accuracy of 12S and offers the equal product to Die-cast Material that can be used AC2A, 2B, 4B, 4C, 7A, 9B, A390, ADC10, AH-14   Thickness Automobile related Home appliance related For Die-cast, general thickness 2.5mm Depend on work size, 　 thickness 2.0mm Cooling fin, advanced 1.5mm draft 1 degree Production days Mission (2D:35days, 3D:25days) Cover (2D:25days, 3D:15days) Home appliance (2D:21days, 3D:15days) All machining finishing Data verification does not include Corresponding possible CAD system I-DEAS, UG, CATIA, PRO-E, STEP, IGES, PARASOLID, etc. possible to correspond to all CAD systems. Verification such as draft and thickness before making mould Quality Assurance - Size measuring method - Similar with 3D measurement equipment (contact system) - Internal defect - Cutting, if need - Leak inspection Heat treatment In-house T5, T6, T7 Corresponds to other heat-treatment if need. Impregnation processing Corresponds to the resin and water glass

Difference by various casting processes

Basic type Size accuracy Draft Cast surface Sand casting Wooden/Resin type 1％ 1.5°-3.0° 50-150z Gypsum casting Silicon type 0.3-0.5％ 1.5° 6-25z Precise sand casting (IPSC) Resin type 0.3-0.5％ 0.5°-1.5° 15-35z

IPSC method casting surface roughness measurement data

Region with rough cast surface ROUGHNESS CUTOFF = 0.8mm TRAVERSING LENGTH = 2.50mm MAG. = 2000 Rz = 27.68μm 27.68z ROUGHNESS CUTOFF = 0.8mm TRAVERSING LENGTH = 2.50mm MAG. = 2000 Rz = 27.68μm 29.99z

General region ROUGHNESS CUTOFF = 0.8mm TRAVERSING LENGTH = 2.00mm MAG. = 500 Rz = 2.8μm Rmax = 17.9μm Rz = 10.9μm 10.9z ROUGHNESS CUTOFF = 0.8mm TRAVERSING LENGTH = 2.00mm MAG. = 500 Rz = 3.6μm Rmax = 26.4μm Rz = 14.4μm 14.4.z ROUGHNESS CUTOFF = 0.8mm TRAVERSING LENGTH = 2.00mm MAG. = 500 Rz = 3.4μm Rmax = 25.7μm Rz = 15.3μm 15.3z

[The precise sand mould molding] for the problem solving which directed to mass production.

The 3D data is designated faithfulness as shape, trial manufacture process with the [Precise sand mold molding] is a big advance which can verify the problematical point that occurs when mass-producing in Die-cast at trial manufacture step.

A minute crack with the durable test in the precise sand mold prototype due to concentration of stress is generated in the ↑ section.		With the second trial manufacture which is directed to mass production in problem place with the R attaching measure

[The precision cast product] becomes possible obtaining for reproducibility of thickness and shape the mounting appraisal which equal to the Die-cast.