Iron casting

cast-ironindividualprototyping

We specialize in the casting and precision machining of high-rigidity, high-stability machine tool beds and large structural components. From material selection and process simulation to ultra-precision machining to ±0.002mm, we provide fully controllable manufacturing services to ensure that every product possesses excellent precision retention and long-term stability. Whether it's the machine tool body, transmission support, or functional components, Hansheng is your reliable one-stop precision manufacturing partner.Hansheng Automation provides one-stop solutions for machine tool bed castings and large structural components.In the field of precision manufacturing, 99% of the effort can be wasted due to a mere 1% instability in the foundation. The ultimate performance and long-term precision retention of a priceless piece of equipment stem from its most fundamental element—a highly rigid and stable structural foundation.At Hansheng Automation, we not only cast metal, supply gears, and perform precision CNC machining, but we also engineer an "absolute zero point" for your cutting-edge equipment—a performance foundation that is rock-solid and consistently stable under any operating condition.Hansheng Automation Integrated SolutionsCasting EngineeringProcess Optimization: Engineers use simulation analysis to optimize your design, improve runners, and install risers to ensure uniform molten iron filling, fundamentally eliminating internal defects such as shrinkage cavities and porosity.Materials Science: High-grade gray cast iron (HT300) and ductile iron (GGG50) are selected, with rigorous pre-furnace spectral analysis to ensure material properties meet 100% standards.Core Processes: Resin sand casting and lost foam casting are flexibly utilized to balance complex structures, surface quality, and cost-effectiveness.Precision MachiningLarge-scale machining capabilities: 2100mm horizontal machining centers and large gantry machining centers can perform milling, boring, and drilling of all critical planes in a single setup on a large machine bed, eliminating cumulative errors from multiple setups.Micron-level accuracy: Conventional milling and turning achieves ±0.01mm, while precision grinding and combined milling/turning can control tolerances within ±0.005mm, and ultra-mirror finish machining can achieve ±0.002mm.Quality AssuranceComplete Stress Relief: All castings undergo a full annealing or aging treatment cycle, monitored by professional equipment to ensure complete stress release and long-term dimensional stability.Precision Inspection: Equipped with coordinate measuring machines (CMMs), laser interferometers, and other inspection equipment to provide full-dimensional inspection reports, including dimensions and geometric tolerances.Examples of our capabilities:Printing and Packaging Industry: Foil control frames requiring extremely high flatness and parallelism, as well as emboss main bodies and matching emboss rear bodies requiring precise alignment.Transmission and Automation: The change gear bracket requires extremely strict tolerances for hole center distance and perpendicularity to ensure smooth gear transmission with low noise.Equipment accessories and components: Even functional rear lid plates and operating handle mounting bases are treated to the standards used for manufacturing core components, ensuring perfection in every detail.Technical Specification OverviewCategoryParameterDetailed DescriptionCasting CapacityMaximum Size3800 x 1500 x 1200 mmMachining CapacityMaterialGray Cast Iron (HT200-300), Ductile Iron (QT400-600), Customizable as requiredCasting ToleranceFree Tolerance ±1mmMaximum StrokeHorizontal: 2100 x 1060 mm; Vertical: 1200 x 840 mmAchievable PrecisionSpecified key tolerance up to ±0.03mm, precision grinding/turning and milling up to ±0.005mmSurface RoughnessUp to Ra0.2Quality ControlTesting EquipmentCMM Coordinate Measuring Machine, Spectrometer, Hardness Tester, Roughness Tester, Ultrasonic Flaw DetectorServiceDelivery DocumentsHeat Treatment Report, Full-size CMM Inspection Report (Optional)Value-added ServiceEngineering Optimization Suggestions, Heat Treatment, Surface Painting/Powder Coating, Component Pre-assemblyThe Process of Working with Hansheng AutomationTechnical Consultation and Drawing Analysis: Provide your 2D/3D drawings, and engineers will conduct a Design for Manufacturability (DFM) analysis with you.Detailed Solutions and Quotations: Receive a comprehensive solution including process flow, delivery time, and cost within 48 hours.Mold Manufacturing and First Article Inspection (FAI): CNC automated mold-making equipment is used to quickly complete mold manufacturing and provide a detailed first article inspection report for your approval.Mass Production and Process Control: SPC (Statistical Process Control) is implemented during production to ensure high consistency across every product.Final Inspection and Safe Delivery: After 100% final inspection, professional rust-proof and impact-resistant packaging ensures the safe delivery of your product.FAQ (selected):If your design has issues that could affect casting or other problems, engineers will communicate immediately and offer modification suggestions to improve casting quality and reduce costs without affecting functionality.The delivery timeline depends on the complexity and size of the parts; an approximate timeline is provided after quoting."Specified tolerance ±0.03mm" refers to critical dimensions or geometric tolerances on customer drawings; "precision machining ±0.005mm" is the upper limit for specific machining processes.Non-standard grades of cast iron or special alloy materials can be specified; material engineers will assess feasibility and make procurement as needed.Key Features / Technical Specifications:Maximum casting size: 3800 x 1500 x 1200 mmMaterials: Gray Cast Iron (HT200-300), Ductile Iron (QT400-600), customizableCasting tolerance: ±1mmMachining stroke: Horizontal 2100 x 1060 mm, Vertical 1200 x 840 mmPrecision: Key tolerance up to ±0.03mm, grinding/turning/milling up to ±0.005mmSurface roughness: Up to Ra0.2Quality control: CMM, spectrometer, hardness tester, roughness tester, ultrasonic flaw detectorDelivery documents: Heat treatment report, full-size CMM inspection report (optional)Value-added services: Engineering optimization, heat treatment, surface painting/powder coating, component pre-assembly