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Phase
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Description
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Project and Design
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In this phase, the study of the feeding and filling system of the pieces is carried out, and the models and core boxes are built. Computer simulations are used to ensure the quality of the pieces.
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Molding and Coremaking
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The sand molds are made using molding technologies in cast steel such as Green Sand and chemical molding. Additionally, the sand cores are made in the coremaking section.
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Melting and Casting
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The process of melting scrap and ferroalloys to obtain the liquid molded steel is carried out in medium-frequency induction electric furnaces. The molten steel is poured into the sand molds.
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Shakeout
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Through vibration on a vibrating screen, the cast pieces are separated from the molding sands. The cast pieces continue the manufacturing process while the sands are reclaimed.
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Shot Blasting
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The demolded pieces undergo a shot blasting process to remove remaining sand residues using high-speed steel shot projection.
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Cutting and Knockout
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In this phase, the gating systems, feeders, and risers are removed from the pieces through cutting and knockout operations.
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Heat Treatment
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The raw cast pieces undergo special heat treatments such as normalizing, annealing, quenching, and tempering to achieve the desired mechanical properties.
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Deburring
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Operations are carried out to remove burrs and irregularities from the pieces.
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Painting
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The pieces undergo a painting process to protect them against corrosion and improve their aesthetic appearance.
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Bushing Assembly
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Assembly of bushings or other additional components is performed on the pieces as required.
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Piece Welding
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If necessary, piece welding is carried out to assemble components and ensure structural integrity.
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NDT Testing
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Non-destructive testing is performed to detect hidden defects or discontinuities in the pieces.
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DT Testing
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Destructive testing is conducted to evaluate the properties and strength of the pieces.
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Machining
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Operations such as roughing, turning, milling, drilling, and balancing are performed to achieve the required dimensions and tolerances.
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Packaging
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The pieces are properly packaged and prepared for transportation and delivery to the customer.
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