Auto Melt Treatment
Molding Machine
Koyama has achieved reduced as-cast wall thicknesses to 2.5 mm and draft angles to 0.5 degrees. Koyama also utilized Sintokogio to engineer and integrate the auto- pouring system for the mold line, auto-handling system for the ladles from tap out through magnesium treatment to pouring, sand system, and mold conveyor and cooling line. Tis integration is what allows for labor maximization from tap out of one of three 4-ton induction melting furnaces
(the original iron foundry uses cupola melt) through shakeout. Prior to adding the new iron facility,
Koyama’s total production was 4,300 metric tons per month. In 2010, the firm averaged 5,500 tons per month.
Advancing Cleaning & Finishing
From 500-employee facilities to 20-man shops, many North American metalcasters are installing automated casting grinding systems designed for job shops to improve the consistency,
efficiency and quality of castings leaving the cleaning room. In addi- tion, these systems replace the labor requirement in one of the toughest departments in a casting facility. For Koyama, outside suppliers of
automated equipment were too expen- sive or the technology didn’t fit the casting environment. As a result, the firm developed its own double-head automated grinders and has continued to develop the systems ever since. Ten, in the late ‘90s, the development caught
July 2011 MODERN CASTING | 21
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