Ang aming pattern shop ay gumagawa ng mga pattern na gawa sa kahoy o resin mula sa iyong pagguhit, OEM sample o numero ng bahagi. Dinisenyo ang mga amag na may tamang allowance sa pag-urong, draft angle at sistema ng pagpapakain para sa bahagi.

Bakit ito mahalaga: Ang shrinkage allowance at feeding design ang magpapasya kung ang isang casting ay lalabas sa dimensional na tama at panloob na tunog. Ang pattern na tama para sa isang haluang metal ay kadalasang mali para sa isa pa, kaya ang pattern ay tumugma sa materyal na ibinubuhos.

Kontrol sa kalidad: Dimensional check at 3D na pag-verify ng pattern bago ilabas sa produksyon.

Papasok na scrap ng bakal, Ang mga pig iron at ferro-alloys ay siniyasat para sa chemistry at kalinisan. Ang inaprubahang materyal ay inilabas sa melting shop na may panloob na numero ng batch.

Bakit ito mahalaga: Walang heat treatment o machining step ang makakapagtama ng masamang chemistry. Ang kontaminado o maling pagkakaayos ng scrap ay ang nag-iisang pinakakaraniwang sanhi ng out-of-spec na manganese heat, kaya ang materyal ay napatunayan bago ito umabot sa hurno.

Kontrol sa kalidad: Pagsusuri ng spectrometer ng papasok na materyal na haluang metal; tingnan ang kalinisan ng paningin sa scrap.

Ang pagtunaw ay isinasagawa sa medium-frequency induction furnaces na may sukat mula sa 1.25 t sa 5 t depende sa timbang ng paghahagis at laki ng batch. Final chemistry and temperature are adjusted in the ladle.

Bakit ito mahalaga: Carbon and manganese content determine whether the austenitic structure will be stable after heat treatment. Pouring temperature decides how well the mould fills and how much shrinkage porosity ends up in the finished part.

Kontrol sa kalidad: A spectrometer sample is taken from every heat and the result recorded before pouring is authorised.

Moulds are produced by lost-foam (EPC), V-process vacuum moulding or sand casting depending on the part geometry and quantity required. Cores for internal cavities are made and assembled.

Bakit ito mahalaga: Mould hardness, coating and core positioning control surface finish, dimensional accuracy and which defects a casting will tend to develop. The process route is selected per part rather than applied uniformly.

Kontrol sa kalidad: Visual and dimensional inspection of the assembled mould, plus core position check, before pouring.

Molten steel is poured into the moulds at a controlled temperature and pouring rate. Risers and gating systems feed the casting as it solidifies.

Bakit ito mahalaga: Pouring too cold produces misruns and cold shuts; pouring too fast erodes the mould. Feeding design determines whether the last section to solidify receives liquid metal or ends up with shrinkage voids.

Kontrol sa kalidad: Pouring temperature and time are logged for every casting, and traceable to the heat number.

Castings cool in the mould for the prescribed time, then the moulding sand is removed. Risers and gating systems are cut off and the raw casting is cleaned.

Bakit ito mahalaga: Cooling too quickly in the mould creates internal stress that can cause cracking during heat treatment or in service. The cooling time is set by section thickness rather than by production convenience.

Kontrol sa kalidad: Visual inspection of the raw casting for surface defects; section thickness check on critical areas.

Solution treatment and water toughening for manganese steel; quenching and tempering for high chrome alloy and alloy steel. Furnace size is matched to the casting so that it heats evenly.

Bakit ito mahalaga: This is the step that creates the material properties. For high manganese steel it dissolves carbides back into the austenite so the part work-hardens in service instead of failing early; for high chrome iron it develops the martensitic matrix and carbide structure that give the hardness.

Kontrol sa kalidad: Furnace records are kept per batch, and hardness is tested after heat treatment before the part moves to machining.

Castings are brought to OEM dimensions by CNC and conventional machining, including turning, milling, drilling and tapping. Large vertical lathes and hydraulic straightening presses handle oversize parts and distortion correction.

Bakit ito mahalaga: Wear parts are fitted onto existing crushers and mills, so mounting faces, bolt holes and locating shoulders have to match the original geometry. Dimensional error here shows up as premature bolt failure or uneven wear in service.

Kontrol sa kalidad: Dimensional inspection against the customer drawing, using calibrated gauges and templates for every critical dimension.

Final inspection is completed and the documentation package is compiled. Parts are packed in steel-framed wooden cases lined with waterproof film, with shipping marks per customer requirements.

Bakit ito mahalaga: The documentation package is what allows a plant to accept the parts into stores and to trace them later. Packing determines whether heavy castings arrive undamaged — and whether the mounting surfaces still meet tolerance after a long ocean voyage.

Kontrol sa kalidad: Final inspection before packing, with a photo record and a complete document set for the shipment.