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    INNOVATIVE CASTING
    TECHNOLOGY

SERVIZI INTEGRATI

A Full Scope Approach

Fonderia Boccacci Group is composed by the Cast Iron Foundry and the Machining Shop..

The cast iron castings that we produce are the result of our Research & Development, which allows us to carry out tailor-made projects, created in partnership with our Customers to best satisfy their needs.

For many years our company has developed new materials and production technologies that have allowed us to transform commonly used materials and traditional construction and assembly systems, ensuring better performance and allowing efficiencies in the Customer's assembly and production lines.

Our Quality and Production systems guarantee repeatability for the entire range of our production, from “one shot” to series productions, for the entire cycle of activities, consisting of: Pattern Design, Creation of Models and Core Boxes, Creation of Castings, Machining, Painting and complete assembly of the Bill of Materials.

Fonderia Boccacci.

Advanced
Co-design
Design Consulting: we offer a tailor-made service to accompany the customer step by step in the design of the product for both new creation and as a modification, consulting the customer on the most advantageous and advanced technical solution to guarantee costs, repeatability and quality.
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Automatic
Plant
Our unique in the world automatic plant allows us to produce castings from small sizes up to 7mx2.5m x h1.5m+1.5m. The automatic plant is integrated with the pattern warehouse, core boxes and moulding boxes. All equipment is on-line and automatically goes into production when needed.
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Control
We offer a 360° service of control, for all types of cast iron we produce, with dedicated staff and equipment inside our factory.
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Machining
& Assembly
In our in-house Machining Shop we have high precision machining tools to ensure the highest levels of quality, perform all types of required machining and meet high production capacity criteria.
After processing, we carry out dimensional checks on the parts and, when requested, we proceed with painting and assembly with the Bill of Materials required by our Customer.
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Advanced Co-design


INTEGRATED SERVICES

Advanced Co-design & Development

We offer a tailor-madeservice to accompany the customer step by step in the design of the product both as a new creation and as a modification, suggesting to the customer the most advantageous and advanced technical solution to guarantee costs, repeatability and quality for castings and machining.

Our technical office consists of four drawing and design stations with access to all types of 2D and 3D formats as well as two stations for pouring simulation.

Design
Consulting

The design is carried out in co-design with our main customers in order to obtain the best economic and manufacturing result, also with the transformation of the material from composite steel to cast iron, followed by the development of the machining phases.

Furthermore, during the design we create the necessary geometries to ensure non-destructive testing.

We manage and carry out the design of the patternl respecting the geometries, interferences and minimum required tolerances deriving from FEM analyses.

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Advanced
Simulation
Fonderia Boccacci produces cast parts with complex geometry subject to high stresses. In our engineering department we use a number of simulation programs to test and support the casting design and casting system before starting production.

To guarantee a complete pre- and post-casting analysis service, we have two stations for simulationswith 64-core clusters , for a complete series of analyses: the cooling simulation allows us to predict the possible emergence of defects, minimize them and prevent them through an iterative process.

Mould filling simulations allow us to accurately model and size our casting system and avoid anomalies during the filling process.

We also perform simulations of filling speed, micro-structure, defects and much more.
Pattern Design &
Creation

Once the final 3D model has been validated by the customer, it is used to create the model and the related core boxes.

Our network of partner milling shops is equipped with cutting-edge technology such as 5-axis machines capable of guaranteeing maximum precision and perfect replicability of a single pattern.

Our patterns are made of plywood, resin or aluminum and are embedded in molding plates that allow us to introduce the model in our automatic plant.

We have in-house pattern shop for modifications, combined model change and maintenance.

Automatic Plant

INTEGRATED SERVICES
Automatic Plant

Our unique in the world automatic plant allows us to produce castings from small dimensions up to a footprint of 7x2.5m for a height of 3m (1.5 + 1.5).

The plant's in-line structure guarantees 100% repeatability of production, in full safety for the operators.

The plant is integrated with the warehouses for patterns, core boxes and moulding boxes. Thanks to our automatic vertical warehouses, all equipment is in-line and automatically goes into production according to the schedule.

100% Internal Core
Production

Large size hand produced cores


In the semi-automatic system, all movement is motorized, with three mixers that can simultaneously use different sands according to needs and drying with hot air ovens. The core department communicates and operates with the vertical warehouse dynamically, holding the cores in the warehouse during the chemical reaction and preparing them in time for the call into production.

Shot Cores


Automatic moulding and motorized handling plant with three types of sand and different additives according to the product needs. We have three core shooting machines of 60lt, 120lt, 160lt with both horizontal and vertical core box extraction. The core department communicates and works with the vertical warehouse in total autonomy both for the loading of the core boxes and for the storage of the produced cores.
Mechanized Plant for Manual Core Manufacturing

Core Shooting Plant

Moulding Preparation
and Core Assembly Plant


The automatic moulding plant consists of two stations for the preparation of the pouring system. All work instructions are digitized and accessible in real time at the time of preparation. After filling the moulding box, the sand is automatically compacted.

The chemical reaction takes place on 4 levels before arriving at the stripping station which takes place via an automatic manipulator.

The manipulator allows the mould lifting operation without strain on the pattern, allowing a longer life of the pattern without extraordinary maintenance and ensuring repeatability to the gemoetries even after thousands of mouldings. The painting takes place through a mobile platform that allows to reach all areas of the mould in a homogeneous way.

All the moulds are then dried before reaching the underground automatic warehouse waiting for the call-off in one of the 9 assembly bays. After the assembly of the cores, the closing of the moulding boxes is done with a manipulator on a floating platform to ensure optimal alignment.



Core Shooting Plant


Painting Plant
Melting
Plant

Static Pour

The melting plant is composed of medium frequency duplex furnaces with a capacity of 20 Tons/hour and two low frequency furnaces of 15 and 5 T.
During casting, special raised platforms allow the operator to pour safely and ensure accurate control of all phases.


Large Mouldings Casting Line

Centrifugal Casting Line

2 vertical centrifuges and one horizontal shell centrifuge.
The shells with elliptical geometry are finished and painted with a robotic system.


Centrifugal Casting Line
Shake Out


The 8mx8m shakeout plant is currently the largest in Europe.
A manipulator is used to move the moulding boxes and allows to operate safely without damaging the castings.





Deburring
and Sandblasting


Sandblasting and Deburring are both performed internally under quality control supervision, providing real-time feedback to the technical department and production on the results obtained.

The deburring is not only manual but also performed automatically by using 2 numerically controlled robots for up to 7 m long castings, which are able to perform the calibration points on the casting before the deburring operations.



Deburring Robot


Manual Deburring Rooms


In-line Check
Internal
Heat Treatment

We can perform a heat treatment with a furnace of 7.5 x 3 x 2.5 m which reaches a maximum temperature of 1100 °C and can carry up to 80 Tons.

The heat treatment furnace can be used to perform the following processes, totally autonomously (with the automatic creation of the diagrams and curves of the required thermal cycles):
Relaxation, Ferritization, Normalization

Painting and
Drying Area

In order to guarantee the high quality of the painting, the castings are pre-heated and after the painting operation, they are dried in the furnace.

The change of paint is managed automatically by a computerized multi-split system.

QUALITY CONTROL

Quality Control
Internal Quality Control

The quality control department plays a key role within the company and monitors the entire production process, starting from consultancy in the initial design phase of the technical office, up to testing and delivery of finished products. Customers have the possibility to interface directly with the quality department for any need. The testing staff is able to carry out all the main non-destructive tests internally according to standard procedures or procedures in accordance with the customer’s specificatons. If a special test is required, a series of qualified external laboratories can be employed.

Control
of the Process
To ensure the highest quality levels, each phase of the process includes control steps starting from the verification of the incoming goods up to the shipment of the finished product. Some of the tests that are carried out are:

Incoming checks: : all supplies are verified in accordance with internal specifications (e.g. chemical analysis of cast iron, sand granulometry, dimensional control of the model, etc.) Chemical Analysis: with 36-element spectrometer and Leco Carbon / Sulfur analyzer

Thermal Analysis: using our Leonardo software, developed thanks to internal research over several years, we are able to control the spheroidization process in real time and provide a forecast of the quality level of the metal in the ladle before that it is poured, thus allowing the necessary adjustments.

Sand Quality Control: the mechanical characteristics of the sand of each mixer are checked daily by means of special specimens tested with dedicated machines. In addition, penetration checks are carried out.

Painting Checks of Moulds and Cores: the characteristics of the paint are checked daily with special instruments to ensure the correct level of viscosity.

Final checks: all products are checked at the end of the process in accordance with internal specifications and customer requests.


Leonardo System


36-element spectrometer

Non Destructive Tests




Three-dimensional Microscopic


S.E.M.

The testing staff is able to carry out all the main non-destructive tests internally according to standard procedures or procedures in accordance with the Customer’s specifications. If a particular test is required, a series of qualified external laboratories can be employed. Some of the tests and equipment used areo:

Visual Test

  • Vidoendoscope with GE adjustable head probe
  • Videondoscope with fixed probe
  • Direct and indirect visual verification set
  • Light meters with probe for natural light and black light
  • SCRATA Comparators
  • BNIF Comparators
  • MITUTOYO roughness meter

Liquid Penetrating Test

  • Contrasting color penetrating liquids
  • Fluorescent penetrating liquids

Controllo Magnetoscopico

  • MAGISCOP 6000/5000 AC / DC wheeled generator + powder thrower
  • AC/DC yokes of different power and size
  • Digital magnetic field meter
  • Residual magnetism meter
  • Portable UV light reflectors with battery and mains socket
  • Fluorescent liquids
  • Contrasting color liquids
  • Magnetic powder

Ultrasound Test

  • UT GE instrument model USM GO
  • UT GE model USM 36
  • PHASED ARRAY Mentor model too
  • Probes of various frequencies (1-2-4-5 MHz) and types (angled, flat, double and single crystal, with longitudinal and transverse waves)

Hardness Test

  • Fixed hardness tester
  • ERNST type portable hardness tester
  • Portable POLD type hardness tester

Micrographic Check

  • DINOLITE-type digital microscope
  • LEICA 3D viewing optical microscope
  • LEICA portable optical microscope
  • PRESI incorporating press
  • PRESI metallographic cleaner
  • REMET miter saw
  • NIKON optical microscope

Paint Check

  • Digital thickness gauges for paint ELCOMETER, DUALSCOPE
  • Densimeters
  • Pull off test
  • Cross cut test
  • Salt spray test
  • Bresle Kit
  • SO surface comparator
  • WFT control combs
  • Dust tape Kit
  • Ford Cups
  • Thermohygrometers
  • Holiday test
  • Digital thermometers
  • Contact thermometers

Radiographic Control

  • Portable radiometric instrument
  • X-ray viewer
  • Densitometer

Dimensional Check

  • Laser Tracker
  • Measurement Set
  • 3D Scan
  • Renishaw measurements
  • Tracking


Fatigue Test


Compression Test


Tensile Strength Test
Mechanical
Tests

For each casting we carry out mechanical tests in order to guarantee the conformity of the product to the required characteristics.
Some of the tests we can carry out are:

Tensile Strength , Yield and Elongation Test
Resilience test : carried out down to a minimum of -80 ° C
Fatigue Test
Compression Tests

X-Ray

X-Ray with technology of 3 linear accelerators type VARIAN Linatron M3A, M6A and M9A .

The highest quality in non-destructive testing with the ability to penetrate beyond 400mm.

For the less accessible areas, perform x Ray with Cobalt source .



X-Ray


X-Ray


Certifications

We interface with external bodies for any type of certification of the product requested by the customer (3.2)

We also have 6 process certifications (BV, LR, DNV-GL, RINA, KR, ABS) and all the main system certifications (Quality, Environment, Safety, Energy, IRIS)

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