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.
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.
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.
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.
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.
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.
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.
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.
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
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.
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.
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:
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
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 .
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)