Our Expertise and Achievements

We receive a request for cylinder head made of nodular graphite cast iron. Unfortunately, after the product shape is confirmed it is difficult to make it.Then how should it be solved?
Actually, it depends on the product shape.
It is necessary to add a lot of cylindrical risers in order to make shrinkage generated during FCD casting out of the product. We aim for directional solidification that the final solidification becomes a riser. When the product has a flat shape to which a riser can be attached, it is highly possible to be manufactured.
We analyze and simulate the layout of the riser until we get satisfied with the result then cast it.
Because we were able to model the water jacket and the shape of the riser connection freely, we actualized the directional solidification and suppressed the occurrence of shrinkage inside of the product.

We manufacture castings with short delivery times by using a sand-type laminated 3D printer. (The shortest delivery time: 7 days)
The process can be shortened without “the pattern for sand casting” so that it enables quick delivery. Since you do not have to think about punching with a pattern, you can make castings in any shape.
You can also expect the cost reduction. In most cases, it will be cheaper to make one or two items which do not require any correction with the 3D printer than making a pattern.

When the shape of the product is thin-walled but complex (cylinder head, etc.), we propose a runner design that makes the initial flow velocity of the weir as slow as possible within the target casting time.
On the other hand, when the shape of the product is thick and simple (bracket, etc.), we propose a runner design that makes the flow velocity as fast as possible within the target casting time.

The following is what we consider when we design the complex core assembly plan.

• ・Position stability when setting the passage core
• ・Retaining of the core grid and the formability
• ・Blow moldability of the form of the core
• ・Taking sand molds out of the pattern
• ・Changing the product shape

We take all the above into consideration then propose to add core prints and/or the division position of the core. Our proposal gives you some ideas of cost reduc

Casting residual stress analysis values ​​can be estimated in Nastran format. It opens the way for use in the design analysis software that your company uses. Excess thickness of the draft angle, parting edge, dam marks, etc. are analyzed with the accurate casting shape. (If Taguchi Pattern Works made the pattern.)

In the heat treatment of aluminum, excessive residual stress may be generated to the product during quenching after solution treatment. It is simply because the material is rapidly cooled with water from a temperature of 500°C or higher.
This may cause cracks so changes in the design shape is required.
We predict a crack risk in advance and it lead to reduce the number of prototypes.
When there is a large difference in wall thickness, excessive residual stress tends to occur.

You can check whether the core has enough strength to handle. This prevents troubles that cannot be cast, such as being damaged when lifted. Contributes to reducing the number of prototypes.

Because water jacket cores are located inside of the products, once veining occurs, it leads to casting defects.(Water jacket flow channel may get closed.)
To prevent these events, design need to be changed.
We perform thermal expansion stress analysis to predict where the veining occurs. This leads to decreasing the number of prototypes.

No matter how well you think and prepare, you can still fail. However, failures can lead to limitations of phenomena and new findings.
This is especially true for unprecedented prototypes. Accumulation of considering and recovering from past failures creates the current quality. That’s why we value our failure case database. The figure is an easy-to-understand failure.