Castingis at its simplest, the process of shaping melting material or ores by pouring into various moulds. The ultimate aim of Casting is to melt substances to convert them into functional and beneficial products. Metal injection, or die casting, is a metal casting process performed by pressing molten metal into the mould cavity under high pressure. The mould cavity is shaped and formed by using two hardened tool-steel moulds which have been treated to resemble an injection mould. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, tin, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used. Aluminium, zamak (an alloy of zinc and aluminium), brass, magnesium and lead are the most commonly used metals and alloys in metal injection.
The casting process takes place in the Foundry. The Foundry is the place where high quality products are produced by casting melted and liquefied metals in a mould to obtain the desired shape once cooled.
High Pressure Casting
High Pressure Casting which is the most favoured method in the production of aluminium parts offers a price advantage in not only high-quantity production (mass production) but also allows for even complex-shaped products to be produced to a high quality standard.
KALKANCI has an 18 process-controlled Aluminium Cold-Chamber Casting Bench with a clamping force ranging from 4000 kN to 20,000 kN. Eight of these are equipped with industrial robots that guarantee consistent quality even when processing high volumes. Through the online production management system, online monitoring and planning is carried out for 24 hours per day and data collection is automated. In accordance with the above, our other equipment is as follows;
- All our benches have automated mould lubrication robots.
- All our benches are supplied with raw materials from a fully automatic ladling system and seven of these have dosing furnaces.
- Our production is enabled by eight 6-axis casting robots that work in accordance with the cell system, providing the most affordable price advantage together with the highest quality standards for high-quantity parts orders.
Our goal as KALKANCI is to keep increasing our efficiency and price advantage by making all of our benches suitable for the cell system in the very near future.
The KALKANCI team provides quality checks by collecting samples from products both in the alloying process and in the billet process after casting in order to ensure product quality and customer satisfaction is maintained at the highest level.
Doruk Otomasyon and the Manufacturing Operations Management Process
Thanks to our powerful cooperation with Doruk Otomasyon, a company implementing Turkey’s leading production management systems, we are able to collect data from all our benches and from our CNC processing centres on a 24/7 real-time basis.
By tracking our operations in real time and by offering continuous feedback on our production based on certain criteria, we have the ability to increase our efficiency and functionality.
In addition to making real-time programming, we achieve better production outcomes by analysing and identifying the root causes of enterprise losses which are usually not noticeable; such as drops in speed, stops, failures, holding, quality losses, etc. Our journey of transitioning of smart and digital factories within the frame of Industry 4.0 is ongoing with our continuing development and investment.