Before casting phase can take place in our foundry, with technical drawing at hand or on modified parts without technical drawing which requires a complete reverse engineering, we follow the below mentioned steps to reach a phase where, within our foundry inside our model-house our modelists produce core boxes, runners and ingate systems.

Stages in Pattern and Mould Production

USE OF ANY 2D DATA or DIGITIZE PARTS TO HAVE 3D PARAMETRIC CAD DATA
Able to import all kinds of file formats. (Igs, Step, Vda, Ug, Catia, Ideas, Pro/E, Parasolid, Sat, Set, Dxf, STL, Dwg. ASCII)
Digitize any physical figure in 5 axis If there is no technical drawings.
Bi-directional Associability between 3D Cad file and technical drawings.
Photo realistic representation

DESIGNING TOOLING LAYOUT FROM A 3D CAD FILE
Automatic parting line creation, model thickness, draft check, parametric solid and surface modeling in the same environment.
Production of assemblies depending on production method and technical drawings.

CREATING A 3D CAM DATA OUT OF 3D CAD FILE
Application of different machining strategies and techniques.
Roughing of Casting stock, CAD File, Block. Parallel Roughing Flat Surface roughing
Re-roughing of remaining stock from previous tool path
Finishing such as Z level, bi-directional, High Low, Low High, HRadial, Spiral, optimization of tool Z level or bi-directional paths, Flat Surface finishing
Z level, Bi-directional, contour rest milling of areas left by previous cutter, or remaining stock from any tool path(s)
Contour or Parallel Pencil Tracing
Automatic calculation of side steps of cutters depending on surface scallop
Curve Machining, plunge points of roughing, engraving, contouring, pocketing drilling, tapping, boring, etc.
Collision detection and splitting tool paths to avoid collision depending on cutter length and shape of tool holder.
True solid cutter verification system showing operation time, collision detection of cutter and tool holder, fixtures, accurate zoom, pan, rotation, measure, cutting volume, comparision of CAD data and machined stock.
Post-processing

CNC MILLING MACHINES
3 Axis CNC Machine 1500 mm X 800 X 650 mm
3 Axis CNC Machine 1000 mm X 600 X 550 mm

ASSEMBLY OF A PATTERN OR A MOULD
Various Conventional Milling and copying machines
Hand made techniques of pattern making process
Assembling and testing


Processes

COMPLETE PATTERN PRODUCTION FOR FOUNDRIES
From 2D drawings to finished Patterns including Core boxes, Runners, Ingate systems
Produce any types of core boxes with their proper Core box machines

COMPLETE DIE PRODUCTION FOR DIE-CASTING FOUNDRIES
Aluminum, metal casting dies.

COMPLETE MOULD PRODUCTION FOR PLASTIC INJECTION ESTABLISHMENTS
Plastic Injection Molds with plastic simulation and analysis software. (Runner analysis, solidification, air traps, deformation, density variation, temperature degrading, cooling regions etc)

PROTOTYPE PRODUCTION
Producing different kinds of material such as steel, iron, plastics, aluminum, wood, araldite, polyester etc
Assembling and painting of prototypes.
Production of Rapid Prototype Models.

REVERSE ENGINEERING
Digitizer Gp12 (Volume 2.4m X 2.4m X2.4 m)
Process points of clouds, parametric generation of surface, wire, solid and 3D curve geometries on pieces
Technical drawing generation through 3D data obtained previous step

MECHANISM ANALYSIS
Mass properties, center of mass, moment of inertia of CAD Files (even if imported CAD files)
Automatic Interference Detection of Assemblies
Dynamic Analysis of Assemblies
Mechanical (Stress, moment, Strain, Deformation etc) Nonlinear Analysis
Associated technical drawings, Bill of Materials (BOM), Flow charts