High Pressure Die Casting Factory
Tam otomasyonlu alüminyum döküm presleme sistemine sahip tesisimiz otomotiv, aydınlatma, beyaz eşya, ısıtma ve havalandırma sistemleri gibi sektörler için alüminyum parça üretimi yapmaktadır. Fabrikada her bir tezgahta entegre edilmiş bekletme ocakları, otomatik kalıp spreyleme, parça alma robotları ve 400 tondan 1.250 ton kapasiteye kadar 14 adet presi ile 20 gramdan 8,5 kilograma kadar üretim gerçekleştirilmektedir. Kormetal, müşterilerin beklentilerini karşılamak için 47 yılı aşan tecrübesini son teknoloji ile birleştirerek uluslararası kalite standartlarında alüminyum döküm ürünler üretmektedir.
Production Units
R&D and Design
In our R&D center, all processes from the design of the product to the manufacturing stage are checked for aluminum parts for sectors such as heating, ventilation, white goods, automotive and lighting. Risk and feasibility assessment is made for aluminum parts produced in line with the demands of our customers. After the pre-prototype experiments created with computer aided modeling and analysis, the piece, which is determined to be suitable for production, is presented to the customer's approval.
Some of the software used in the R&D Center
- Novacast casting simulation program
- Solidworks
- Powermill
- AutoCad
- Mastercam
Project Management & Engineering
In our engineering department, upon the request of new products from customers, firstly a risk and feasibility assessment is made and an offer is submitted. In this process, the APQP plan is prepared and the process flow chart is determined. FMEA analysis is made to decide on the most appropriate design. The design created with computer aided modeling and analysis is presented to the customer's approval after the pre-prototype trials. The measurement system is approved by conducting an MSA study. PPAP documents are issued and sent to the customer. When the tests are completed successfully, the production of mass production molds, fixtures and equipment begins. In this section, all processes from the design of the product to the manufacturing stage are checked and improvements are made. Computer-aided programs such as Novacast, Solidworks, Powermill, AutoCad and Mastercam are used in the processing and deburring phase.
Remelting & Casting
High pressure casting plant has 14 cold chamber horizontal injection presses with capacities ranging from 400 tons to 1,250 tons. Casting parts between 20 grams and 8,5 kilograms in varying sizes can be produced in our facility. All presses are equipped with automatic dosing cooker, automatic lubricant, piece pickup equipment and 6 axis robots. Thanks to all these equipment, error-free compliance and stable production is ensured for the production parameters. In addition, vacuum equipment can be used for other suitable projects. Our facility, which has a daily melting capacity of 60 tons, can produce with 5 different alloy types.
High Pressure Die Casting Plant Machinery Park
- One 1.250 ton press
- One 1.000 ton press
- One 900 ton press
- One 800 ton press
- One 750 ton press
- Three 630 ton press
- Four 500 ton press
- One 400 ton press
- Three ABB 6 axis parting robots
- Two Kawasaki 6 axis pick-up robots
- Three 2 axis Spesima taking robot
- Three camera control systems
- One X-Ray device
Remelting Plant Machinery Park
The high pressure die casting factory can produce with a daily melting capacity of 60 tons and 5 different alloy types.
- Two shaft type Striking melting furnace 1200 kg/h
- Three tilting type furnaces with 800 kg crucible capacity
- One tilting type hob with 500 kg ladle capacity
- 60 tons of remelting capacity per day
- Production opportunity with 5 different alloy types
Trim & CNC Machining
In our high pressure die casting facility, there are 15 trim presses with sizes ranging from 15 tons to 50 tons. In addition, there are 2 shot blasting machines with hanger capacity of 500 kg and 1000 kg, and 2 drum cleaning machines with 300 kg drum capacity.
Trim Unit Machinery Park
- 16 trim presses between 15 and 50 tons capacities
- 2 blasting machines with 500 kg and 1000 kg hanging capacity
- 2 drum cleaning machines with 300 kg drum capacity
- Various sizes of vibration and washing and drying machines
CNC Processing Unit Machinery Park
- 6 BROTHER-S1000X1-16000 RPM CNC processing machines
- 2 CNC-BROTHER-R650X1-16000 RPM CNC processing machine
- 1 GOODWAY-GLS-200 CNC Lathe
Painting & Packaging
High pressure casting factory paint and packaging department; It consists of 3 powder paint booths and integrated paint drying ovens and surface preparation baths.
Painting & Packaging Plant Machinery Park
- 1 robot paint booth
- 3 manual paint booths
- Paint drying oven integrated in 1 paint booth
- 1 continue paint drying oven
Quality
After the high pressure casting processes, during the new product commissioning process, from the entry quality control to the shipment by the project team; Entrance is controlled by quality control, process control, final control and new product sample control departments.
In the high pressure casting center, tests such as surface roughness, hardness, liquid penetrant, paint thickness measurement and radiographic examination are applied. In case of error, detailed 8D study is performed and root causes are identified and eliminated. In order to measure process performances, supplier, process, product, QMS internal audits are performed and the nonconformities identified are eliminated and improvement opportunities are determined.
Quality Certificates
- ISO 9001 Quality Certificate
- IATF 16949 Automotive Quality Management System Quality Certificate
- ISO 14001: 2015 Environmental Management System Quality Certificate
- ISO 45001: 2018 Occupational Health and Safety Management System Quality Certificate
