To ensure comprehensive service we offer clients an additional services eg. mechanical machining, painting, transport and associated service.

MECHANICAL MACHINING

Thanks to our modern machine park we perform mechanical machining of castings. For more details click here: http://odlewy.com/mechanical-machining/?lang=en

PAINTING

On request of the client, we paint the details in order to protect them against corrosion. This is done in a spray or immersion technology.

TRANSPORT

Depending on the needs and possibilities of the customer we accept two transport possibilities:

• personal transport provided by the client
• transport provided by the Simiński-Ordon Cast Iron Foundry based on constant cooperation with the transport company

ASSOCIATED SERVICES

Our goal is to provide the customer comprehensive services in execution of His order. We focus on flexibility and adapt to technical requirements sat by the Contractor. Therefore, beyond the basic service we cooperate with external companies, to provide associated services, like:

• enamelling
• KTL painting
• powder painting
• hot dip zinc plating
• galvanizing

We cooperate just with reliable partners, because we are aware that the level of services provided by them may affect the final evaluation of the entire order and satisfaction of our client.

At Siminski-Ordon Iron Foundry, the focus is on the mechanization of production, so its basis is the DISAMATIC automatic molding lines. Their use allows to maintain high quality and repeatability of produced castings. The equipment in our possession allows for the realization of medium and large series with a diverse assortment.

The mold shop is the heart of the entire foundry. This is where the molds are produced and the liquid metal is poured, so it is important that this process takes place on modern and efficient equipment.

Siminski – Ordon Iron Foundry is in possession of two lines with DISAMATIC automatic machines:

DISAMATIC 131 A (production: 2007/2017) with parameters:

• maximum casting dimensions 500 x 400 x 250 mm
• dimensions of model plate 600 x 480 mm
• maximum casting weight: 25 kg
• maximum capacity: 400 forms/hour
• The length of the mold cooling line 80 m (AMC+SBC)

DISAMATIC D3 Z555 (production: 2016) with parameters:

• maximum casting dimensions 600 x 500 x 250 mm
• dimensions of model plate 750 x 570 mm
• maximum casting weight: 35 kg
• maximum capacity: 555 forms/hour
• The length of the cooling line of forms 85 m (AMC+SBC)

The machines are additionally equipped with attachments for placing cores. This makes it possible to produce high-quality core castings. In addition, the automats are integrated with robots for placing filters.

The model plate exchange system is user-friendly, which dramatically reduces the time to switch the machine to produce a different range of products. Thanks to modern software, the following processes are streamlined:

• Data exchange between the machine and computers in the foundry network
• database collection and management
• production reporting
• archiving of production parameters
• Support and control of preventive maintenance

Types of castings made :

made of gray cast iron:

• EN-GJL – 150
• EN-GJL – 200
• EN-GJL – 250
• EN-GJL – 300
• EN-GJL – HB155
• EN-GJL – HB175
• EN-GJL – HB195
• EN-GJL – HB215
• EN-GJL – HB235

made of ductile iron:

• EN-GJS – 400-18 LT
• EN-GJS – 400-18
• EN-GJS – 400-15
• EN-GJS – 450-10
• EN-GJS – 500-7
• EN-GJS – 600-3
• EN-GJS – 700-2

The melting shop is where liquid metal (gray and ductile iron) is produced. All batch materials used are certified for quality. The composition of the liquid metal is controlled several times so that it meets all standards.

The melting shop at the Siminski-Ordon Iron Foundry operates on a duplex system. Metal is melted in medium frequency induction furnaces with a capacity of 2 x 6 tons and 2 x 4 tons. The maximum capacity of the melting shop is 10 tons/hour (liquid metal).

During the pouring of the mold, a modifier is blown directly onto the metal stream. In addition, the pouring temperature of each mold is measured using an optical pyrometer. All process parameters are archived in real time.

Among the equipment used in the melting shop are:

• Otto Junker GmbM induction stoves
• Hot pourers (with inductor)
• Cold pourers
• Euro-Equip and Yuatsuki scrap crushers

As a part of the machine park in the Simiński-Ordon Cast Iron Foundry is also modern Core shop. As a result, we are able to offer the customer a broader spectrum of products.

Manufacture of the core is made in the technology of amino – cold-box. For this purpose we are equipped with core shooters Laempe LL20 (produced in 2008 and 2014).

After cooled down castings are blast-cleaned using following machines:

• shot-blasting machine CH 15 x 20 / 3W2C / MS / 1.5T
• belt shot-blasting machine B12 x 16S / 2W2C / SK / MS
• belt shot-blasting machine OWT 400 (capacity 400 kg)

All equipment for iron castings moulds knocking out and fettling are dedusted through highly efficient jet filters.

The laboratory, next to the Quality Department, is a key organizational unit which verifies quality of the manufactured details. This is where technical requirements and customer expectations are correlate with the parameters of finished product.

Only the coherence of these two areas allows to successfully finished the production process and provide the high quality product to client.
For this purpose it is necessary that all measurements were made in modern technology environment and by qualified employees.
As a part of the ongoing analysis we conduct following measurements:

• examination of sand in regard to its:
  • permeability
  • humidity
  • strength
• examination of cast iron in regard to its:
  • strength
  • hardness
  • microstructure
  • elongation of ductile iron

All production parameters are constantly monitored and archived.

Among the tooling used in the laboratory there are e.g.:

• equipment for examining parameters of sand:
  • rammer laboratory type LU
  • the camera to measure the strength of sand type of LRU – 1
  • instruments for examining permeability type LPiR – 1
  • moisture analyzer for examining humidity of sand

• equipment for examining the strength and hardness of the cast iron
  • testing machine to the statistical tests type ZDM-30
  • hardness BRINELL type B-2

• metallographic microscope to study the structure of metal

• emission spectrometer to measure the chemical composition

The Simiński-Ordon Cast Iron Foundry has its own design department, what definitive accelerates the execution of an order. We provide professional support of many years of experience in the design of castings. Our qualified employees are willing to help and advise.

Every order is sent to the design department, where on the basis of provided technical requirement or pattern, we design 3D blocks using CAD software. Then, to avoid errors, each project is transferred to the simulation program of filling and solidification forms – NOVAFLOW & SOLID 6.0. This enable to conduct optimization before perform all the toolings, which positive affects on quality of products. Knowledge and experience of our designers, combined with innovation technology, allow us to meet the expectations of demanding clients and realize the most complex projects.

Each project, after achieving a positive result in the simulation program, shall be forwarded to the machining department, where pattern plates are performed. Its production is carried out by using the software Esprit. Engineers of design department develop individual software machining programs which are sent to the CNC machining center (3 or 5 axial). This allows us to implement highly sophisticated tooling, maintaining the highest parameters of accuracy.

On the next stage the technician sets the pouring parameters including: composition of the cast iron, temperature of poring, necessary to apply filters.

After perform a tooling and determine all the parameters of the process there is high time for testing. Everything is systematically verify by the quality control department, so that making decision of permitting a product to a production stage didn’t questionable.

We are always ready to respond to the expectations of the customer, which is why we allow to prepare pattern plates at the headquarters of the Contractor. In this case, our engineers develop the project of 3D blocs and send technical drawings to the customer. Already performed patterns plate are sent back to the Simiński-Ordon Cast Iron Foundry and then process of casting production is started.

Below we present how it is running a simulation of the solidification process.

Siminski – Ordon Iron Foundry offers machining of castings, and making of casting molds (model plates) for both in-house and external companies. Models are made from 100% metal, providing durability from 50,000 to 300,000 moldings.

Our advantage is having our own laboratory with modern coordinate measuring machines. The equipment we have allows us to perform measurements with an accuracy of up to one micrometer, as well as to examine the relationship between the various dimensions of the casting. As a result, we are able to provide the highest quality to even the most demanding customers. For more information, visit obrobka.com/en

The machining department has the following machines:

1. 5-axis vertical machining centers,
2. vertical 4-axis machining centers,
3. 3 axis vertical machining centers,
4. horizontal machining center 4 axis
5. CNC vertical lathes with driven tools,
6. CNC horizontal lathes with driven tools
7. robotic turning centers
8. column drills
9. metal cutting saw
10. KOYAMA automatic grinding machines
11. All common measuring tools and among others:
    • MAHR and FUTURO roughness measuring instruments
    • MITUTOYO sensor dial and electronic diameter gauges
    • calipers, depth gauges
    • and others

We operate according to system of quality management based on the PN-EN ISO 9001: 2009 standard and environment management based on the PN-EN ISO 14001: 2005 standard. The certificates were received in 2005 and 2008 respectively and there are renewed every year.

Quality Control department is a key organizational unit of the casting process.

Within its range of activities there are all processes verifying compliance of the finished part with the requirements of the technical drawing, so that the customer receives high quality product. Verification process includes mainly dimensions of the casting and surface quality.

Quality Control Department participates in process of implementing  new casting production, closely by controlling and giving an opinion of the parameters of sample casting. It also takes an active part in examining complaints.

After detailed casting control customer receives a certificate with guarantee of quality (compliance with requirements of the technical drawing).

We make every effort to assure the process of quality control has been implemented efficiently to meet the customer’s expectations in terms of both product quality and delivery time.