Company Presentation - Denizciler Dökümcülük Sanayi
DENİZCİLER DÖKÜMCÜLÜK SAN. VE TİC. A.Ş. COMPANY PRESENTATION 2015 About Us : Founded in 1978 • Total production capacity app. 24.000 Tons/year. Total area 25.000 sqm., covered production facilities 14.000 sqm. 200 qualified employees. Our main activity is; the production of gray and ductile iron castings. their machining heat treatment, coating and hot dip galvanizing. Single Part weights; from 0,5 kg./piece to 15000 kg./piece Various approvals including ISO 9001, Where we are: Corporate Information : Full Name & Address: DENİZCİLER DÖKÜMCÜLÜK SANAYİ VE TİCARET A.Ş. Kutlu Aktaş Cad. No:23 ALOSBI 35800 Aliağa IZMIR/TURKEY Legal Form : Incorporated Company Establishment Date : 03.12.1981 Tax Registration Office : Hasan Tahsin Tax Office Tax Id. Number: 292 000 3925 Paid Capital : Memberships : 10.000.000 Turkish Liras Aegean Chamber of Industry No: 10408 Aliağa Chamber of Trade No : 3964 Our Staff : By Position Manager Administration Chief Foreman Master Number 7 By Education Number University Graduate (Engineer) 13 20 University Graduate (Others) 14 1 Vocational College Graduate 7 13 8 Technical High School Graduate 30 High School Graduate 18 Direct Workers 161 Others 128 Total : 210 Total : 210 Production Processes : Pattern Design & Simulation • The CAD/CAM software TOPSOLID , used for designing the patterns, enables us to make 3D Models of the parts to be casted and also to determine the part weights. • 3D Modelling is also the starting point for our casting simulation program QUIKCAST. • Before the actual casting process, the possible problems that may arise from the pattern design or the casting parameters are determined and the corrective actions are taken in advance to resolve these identified problems. • The optimised casting parameters and the molding design leads to minimized quality problems , increasing our production efficiency. • These optimised parameters are than integrated into product sheets to maintain the best quality during the serial production. • The prepared samples will be checked with 3D Laser scan Faro Arm. The scanned data is checked with the original Cad data received from customer. Pattern Production • Being fully aware of the fact, that quality castings require quality patterns, we attach great importance to pattern production with accurate dimensions and tolerances. • Depending on the required lifetime and the selected moulding line, patterns are made accordingly of wood, aluminium, iron or polystrene. • Our well equipped pattern shop with CNC Centers and our experienced team enables us to fulfill our customers’ requirements in terms of new patterns or modifications within favourable lead times. • The patterns are registered in our ERP system and stored properly in our warehouse after final controls for easy access and maintenance. Sand Preparation •Our fully automatic sand preparation plants are PLC controlled and enable us to achieve best possible results in terms of surface quality for our castings. • For sustainable sand quality, mix preparation is controlled at every batch for compactability, green strength and moisture. •Furthermore, samples are also manually taken and cross checked in our quality lab to ensure that the required specifications are met. • 1 x Simpson Speedmüller 85B Sand Mixer 60 Tons/Hour • 1 x Webac Müller Sand Mixer 50 Tons/Hour • 2 x Hartley Sand Control System • Besides green sand system, we also utilise furan system for our semi-automatic moulding line, as well as for hand moulding. • Omega Spartan 2 Sand Mixer (10 Tons/Hour) with cooling and reclamation system. Core Making • According to the requirements of the castings demanded by our customers, we utilise different kinds of base materials for the production of cores. • Following materials are used for core production. • CO2 Sand • Furan Resin Sand • Chrome Ore Sand • Shell Moulding Sand • Utilised machines are; • 3 x 80 lt capacity cold box machine (CO2 + Carbophen) • 1 x 60 lt capacity cold box machine (CO2 + Carbophen) • 4 x 25lt capacity cold box machine (CO2 + Carbophen) • 6 x 5lt. capacity cold box machine (CO2 + Carbophen) • 4 x 2lt. capacity shell and hot box core machine Moulding •The molding process is rather diversified and depends on the design , complexity, weight and accuracy of the casting. • One of our three full automatic molding lines for parts up to 90 kg single part weights is our DISA MATCH 24 x 28 (Horizontal) • 120 Moulds/ Hour capacity • Mould dimensions 613 mm x 713 mm x 500 mm • 2 x Hunter HMP 20 x 24 automatic moulding lines. • 100 Moulds/ Hour capacity • Mould dimensions 508 mm x 613 mm x 400 mm • Single part weights up to 90 kg. • Automatic pouring and cooling lines. • 1 x Semi-automatic (flaskless) molding line with rollover, operating with furan resin system (OMEGA, UK) • Spartan 2 Sand Mixer 10 Tons/Hour (OMEGA, UK) • Single part weights up to 350 kg. • Mould sizes 1250 mm x 1800 mm x 900 mm Hand Moulding • Prototypes, castings not suitable to our moulding line in terms of part weight and dimensions, as well as parts with smaller quantities are produced with this method. • To this end we have flasks in various dimensions. Flasks with sizes up to 4000 mm x 4000 mm are available. • Single part weights up to 10000 kg for ductile iron and up to 15000 kg for gray iron. Melting & Pouring • Our melting capacity is 14,2 Tons/Hour, • Following induction furnaces are operative at our foundry; 1 x 7200 kg/hr 4250 kw medium frequency furnace 1 x 4500 kg/hr 2750 kw medium frequency furnace 1 x 1500 kg/hr 800 kw medium frequency furnace 1 x 1000 kg/hr 600 kw medium frequency furnace Fettling • After cooling down for specified time periods, the in gates, feeders, as well as the risers of the casted parts are removed. Than the residual molding sands are removed in suitable shot blasting machines and parts are subjected to quality control to determin their status. • The castings approved by our quality staff are than forwarded to the work stations, where they are grinded for their end rough dimensions. • For these operations we utilise the following equipments; • • • • 1 x continuous hook type shot blasting machine (2400 mm x 1500 mm x 1500 mm - 10 Tons/hour) 1 x tumble type shot blasting machine ( 10 Tons/hour) 3 x hook type shot blasting machines (1400 mm x 1500 mm x 1500 mm 2 Tons/hour) 3 x tumble type shot blasting machines ( 1000 kg / hour - ø 600 mm) •10 x wheel grinding machines - 600 mm diameter, 60m/sec • Various air grinding tools •2 Koyama 6 axis automatic grinding machines Machining • The parts casted in our foundry are delivered as machined at customers’ request. • Following machinery is in use in our machining shop • Machining is also outsourced from regional machining shops in case of large order quantitites. • 1 x Vertical CNC 3 Axis (Quaser) x= 1270 mm , Y= 700 mm , Z= 600 mm • 1 x Vertical CNC 3 Axis (Ajan) x= 900 mm , Y= 700 mm , Z= 400 mm • 1 x Vertical CNC 3 Axis (Ajan) x= 700 mm , Y= 700 mm , Z= 300 mm • 1 x Horizontal CNC Lathe (Takisawa) ø 450 mm, Y= 762 mm. • 1 x Conventional Lathe ø 660 mm, Y= 2500 mm. • 1 x Conventional Lathe (Tos) ø 520 mm, Y= 2000 mm. • 1 x conventional Lathe ø 660 mm, Y= 3000 mm. • 8 x Column Drilling Machines ø 30 mm Quality Microstructure Analysis with Microscope to magnify 1500X FARO 3D Measuring Arm/ Faro Gage Lazer Scan Chemical Analysis with spectrometer • 1 x OBLF for 15 elements • 1 x OBLF for 18 elements hardness tester 3000 Kg , Ball Ø10 mm Tensile Testing, Compression Testing, Bending Testing Capacity 20 tons Ultrasonic Inspection (Karl Deutsch) Penetration 120 mm Coating • According to customer specifications the primer coating is perforned at our dipcoating line. • Hot dip galvanising is also performed in-house. Packing & Delivery • The suitable delivery method is determined mutually with our customers . • Labelling is done according to customer specifications. • According to their weight and dimensions, parts are delivered on Euro pallets, in wooden boxes and crates, covered with strectch film. • Loads are secured properly to avoid any kind of transport damage. For machined parts suitable anti-corrosion materials are used. Industries Served : Machine Building Industry Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Gearbox Cover GGG 50 41 kg 480 x 530 x 150 Reduction Housing GG 25 12,5 kg 200 x 180 x 150 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Gearbox GGG 70 160 kg 470 x 560 x 440 Shaft Cover GG 25 60 kg 800 x 450 x 500 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Connector GGG 60 14 kg 400 x 200 x 310 Support GG 20 21 kg 450 x 300 x 200 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Compressor Cylinder Head GG 25 8 kg 400 x 200 x 100 Gearbox Body & Cover GG 20 16 kg – 8 kg 250 x 200 x 410 Part Name Material Weigt Dimensions Reduction Housing GGG 50 9 kg 300 x 200 x 140 Part Name Material Weigt Dimensions 90° Shaft Cover GG 40 45 kg 700 x 600 x 500 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Gearbox Cover GG 25 125 kg 1200 x 1000 x 450 Air Valve Housing GG 25 12 kg 250 x 400 x 120 Pump & Valve Industry Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Water Pump Body GG 25 32 kg 700 x 600 x 240 Pipe Coupling GGG 45 32 kg DN 300 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Cooling Compressor Body GGG 25 120 kg 1000 x 1000 x 650 Pump Casing GG 25 70 kg 553 x 620 x 220 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Impeller GG 25 15 kg Ø 300 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Valve Body GGG 40 250 kg DN 700 Tapping Saddle GGG 40 45 kg 500 x 225 x 180 Part Name Material Weigt Dimensions Actuator Housing GGG 50 590 kg 700 x 500 x 550 Part Name Material Weigt Dimensions Adaptor Body GG G 40 8 kg DN 150 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Impeller GG 25 15 kg Ø 300 Slide Clamp GGG 40 10 kg 250 x 100 x 150 Agricultural Machinery Industry Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Gearbox Cover GG 25 28 kg 500 x 350 x 180 Cover GGG 50 18 kg 300 x 200 x 240 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Bracket GGG 40 12 kg – 15 kg 450 x 350 x 200 Shaft Extension GGG 40 40 kg 450 x 200 240 Part Name Material Weigt Dimensions Part Name Material Weigt Dimensions Shaft Cover GGG 50 9 kg 300 x 200 x 140 Loading Arm GGG 40 14 kg 400 x 200 x 150 Civil Engineering Industry Part Name Material Weigt Dimensions Tube Fittings GGG 40 0,5 kg – 6 kg ¾”-2” Part Name Material Weigt Dimensions Manhole and Cover GG20 - GGG 40 11 kg – 18 kg 400 x 400 x 400 Some of Our References : Contact Informations : ADDRESS: KUTLU AKTAŞ CADDESİ NO:23 ALOSBİ ALİAĞA 35800 İZMİR - TURKEY TEL: 00 90 232 621 55 02 FAX: 00 90 232 621 55 04 WEB: www.denizcast.com EMAIL: [email protected] THANKS FOR YOUR ATTENTION
© Copyright 2024