If you are machining for the semiconductor industry, chances are that you have or have been asked to do.

Rapidly advancing technology is driving high demands for semiconductor components to arrive at smart end products. For that, parts like showerheads, solar panels and integrated circuits found in devices like phones and televisions are required in high numbers. Such components require CVD processes to produce free-standing thin material end products. 

Mostly in semiconductor industry, showerhead is used to evenly distribute or spread a gas state chemical on circuit board or LCD board for the purpose of coating/deposition. 

The gas state chemical goes through the showerhead that has thousands to 10 thousand holes that are evenly positioned and this makes the chemical evenly spread and be coated/deposited on the semiconductor board.  

Whether the showerhead can or cannot EVENLY distribute or spread the gas chemicals on the circuit board, plays a crucial role on determining the quality of semiconductor chips.

A Success Story

We share an experience from one of our customers who uses Hwacheon Double Column Machining Center L3 to successfully produce CVD showerheads.

The Customer

Established since 2013 in South Korea, the customer specializes in machining top quality LCD and semiconductor parts and supplying them to their customers globally. 

The Challenge

A recent project requires CVD showerhead in aluminium and overall size Ø2,000 x 1,700 x 40mm with 67,000 micro holes. Besides quick and prompt delivery, accuracy of each hole below 30μm is of utmost importance. 

Prior to using Hwacheon’s L3, the customer has tried to use its existing vertical machining centers but with unsatisfactory results. The customer hopes to find and use the right CNC machine for such applications as there are high demands in the industry.

The Solution

The only way to distribute chemicals evenly on the circuit board is to have evenly positioned holes on the showerhead. 

Using Hwacheon Double Column Machining Center L3, 67,000 micro holes were achieved. The positional accuracy of these holes on the showerhead a within 10um, even during 14 days (330 hours) of continuous machining. 

Double Column Machining Center L3

Besides its outstanding performance in semiconductor CVD components, Double Column Machining Center L3 is designed to machine long slender parts, large plates or multi clamping applications. 

Double Column Vertical Machining Center L3 features Made-by-Hwacheon BT-40 spindle with 12,000rpm, providing high flexibility to machine parts requiring long X-axis travels at high speed with best accuracy and top-quality surface finishes. 

With travel ranges of X = 3,000mm, Y = 1,800, Z = 500mm, it provides a combination with superior technology, machine design and built.

Also available Double Column Machining Centers L1 / L2 with travel ranges of X = 1,500 to 3,000mm, Y = 950 to 1,100, Z = 500mm.

For other machine demands in terms of size and table load, Hwacheon offers a comprehensive range of high-quality Double Column Machining Centres: 

SIRIUS-1250 / SIRIUS-1350 / SIRIUS-1750 / SIRIUS-2500

Contact us for more info or for a price estimate.

However, incorporating automation into CNC machining can be a complex and challenging process. It often requires careful planning and implementation to ensure success.

When it comes to automating your CNC machine tools, it is essential to consider various factors and to have a well-thought-out strategy in place. The big question isn’t whether to automate, but rather what and how to automate effectively.

What is CNC Automation?

CNC automation transforms how CNC machine tools are used in the production process. By reducing human intervention, it increases your shop floor productivity, reduces costs, improves your working environment, and strengthens the overall quality of your products.

The first aspect of CNC automation is the transfer of workpieces or pallets through the manufacturing process. This involves moving them from one machine tool to another or to supportive devices like washing stations or measuring cells. By doing so, you can streamline your manufacturing process to make it smoother and more efficient, while utilising today’s down-time to increase production.

Another key aspect of CNC automation is the management of information and data. This includes updating production execution plans, optimising resource utilisation and prioritising production orders. Doing so reduces errors and improves overall quality.

What to Automate in CNC Machining

Thinking of what you should automate in your CNC machining process? Typically, CNC automation is broken down into two main components: the physical movement of items, and the streamlining of production planning and management.

#1 Automating Physical Movements

First, consider how you can deploy automated hardware to assist in physical movement and operations on your shop floor. Some of these activities include:

• Transfers of parts which are mounted on pallets or work holding devices to and from the machine worktable.
• Automated parts loading and unloading with the help of robots or mechanical arms onto fixtures.
• Direct transferring workpieces to the machine table or chuck
• Automated tool adjustments or changes
• Gripper and tool changes in robots
• Tool transfers to tool magazines
• Workpiece movements to and from processes like deburring, washing, heat treatment, marking, polishing, and measuring.
• Raw material management and transfers
• Semi-finished product management and transfers
• Easy transfer to measuring systems

The most important benefit in automating these tedious and laborious tasks lies in creating a better work environment for your machine operators. Beyond staff welfare, automation helps to reduce errors, improve speed and efficiency, strengthen part quality, and raise production capacity.

#2 Automated Production Planning

Next, consider how you can deploy automation to streamline your production planning process. There are several aspects to consider here.

a) Information Flows

Automate how information flows between your different data systems, machinery, and cells. This keeps your systems in sync, reducing the chance of errors while improving efficiency.

b) Dynamic Production Planning

Automation helps you to proactively update your production plan based on production orders and their priorities. Orders can be automatically fetched from an ERP system, reducing manual inputs. This ensures that production always runs smoothly with orders fulfilled on time.

c) Improved Machine Operator Guidance

Adequate levels of guidance can be provided to operators. This helps them to take the right actions at the right time, minimising human errors and making the production process easier for operators.

d) Consistent Production Handling

With automation, workpiece manufacturing instructions can be handled consistently. Each production run can be kept constant, with quality maintained.

e) Proactive Resource Management

Improved resource management is another important dimension of automation. These may be anything from fixtures, pallets, grippers, raw materials, to NC-programs, cutting tools, tool data, and off-sets. By monitoring your machining resources and providing reports on any missing resources, production will not be impacted by resource shortages.

f) Monitor Machine and Production KPIs

Automation helps you to better manage the reporting and analytics of machine and production KPIs, such as their utilisation, Overall Equipment Effectiveness (OEE), and availability. The system also provides order progress views, making it easier to track the progress of each order while ensuring that production runs smoothly. You can also gain better visibility over your inventory and work-in-progress jobs.

g) Trace Production History

Finally, the right automation system helps you to record your production history and traceability. This helps to provide a clear picture of what has happened during each production run, making it easier to identify and resolve any issues.

When to Automate Your CNC Machining Operations

Here are some key considerations for manufacturing companies like yours to determine when it might be time to automate your CNC machine operations:

#1 High Workload

When the workload of your CNC machines has increased to the point where manual operations become overly time-consuming or inefficient, automation may be a solution.

#2 Rising Labour Costs

If your staff costs like wages and employee benefits have become too high, you should consider tapping on automation to reduce costs.

#3 Better Quality Control

Automation can help ensure consistent quality by eliminating the potential for human error in your CNC machining operations.

#4 Improve Production Capacity

Are you looking to increase your production capacity and throughput? Automation can help to increase production efficiency by reducing downtime, increasing machine utilisation, and reducing cycle times. Leveraging current downtimes for production purposes can yield significant advantages.

#5 Better Equipment Maintenance

Automation can help to reduce the repair and maintenance costs associated with CNC machines, as well as improve their longevity and performance. (Download our checklist to improve CNC machine maintenance here.)

#6 Strengthen Competitive Advantage

To stay ahead of your competition and be the first to market, you need to invest in the right CNC automation technology. This also allows you to stay abreast of the latest trend towards automation in the manufacturing sector.

Automating CNC machine operations can bring many benefits to manufacturing companies, including increased efficiency, reduced costs, improved quality control, and better competitive advantage. 

By carefully considering the above factors, you can determine when it might be time to automate your CNC machine operations.

Benefits of CNC Automation

Should you invest time and money in automating your CNC machining processes? Consider these benefits.

#1 Enhanced Part Precision

Automated part handling results in consistent accuracy. With the right measuring systems in each CNC machine, you can accurately find each part reference point and adjust the CNC programmes accordingly.

#2 Shorter Lead Time

By constantly keeping your production running with unmanned operations, you can enjoy shorter lead times. The flexibility to produce parts on demand enables you to achieve fast turnover times for urgent orders.

#3 Reduced Setup Time

With less manpower required for individual machine operations, part handling and setup is done at designated loading/unloading stations without any disruption to the production line.

#4 Decreased Cycle Time

Operations can be synchronised in overlapping runs, allowing two or more different machines to perform operations simultaneously.

#5 Lower Cost per Part

Enjoy significant cost savings from transitioning to 24/7 operation, as well as reduced downtime and shorter loading/unloading processes.

#6 Space Savings

Consolidating machining operations with automated solutions leads to less floor space being used.

#7 Unmanned Operation

Reduce your manpower costs as a single system can be managed by a single operator.

#8 Improved Machine Monitoring

Reports on machine efficiency can be received and the system can be monitored remotely, even during overnight hours.

#9 Simplified Fixtures

Save your production costs by eliminating complex fixtures.

#10 Efficient Tool Usage

Automation helps you to save on tooling costs by eliminating tooling redundancy.

#11 Increase Worker Safety

The work environment is made safer, especially for the movement of heavy workpieces.

CNC Automation Challenges and Solutions

What are the major challenges in automating your CNC machining jobs and how can you solve them?

Let us look at these CNC automation challenges and solutions here.

Challenge 1: Need to Increase Production Capacity

Every company wants to increase its production capacity, business volume, and profits. Manufacturing orders are often smaller batch orders, which require machinery and operations to be flexible. 

To address this, companies can incorporate smart planning and utilize non-productive times, such as breaks and overnight operations, to make more efficient use of machines and manpower. This results in faster production cycles and more cost-effective operations. 

Additionally, using production techniques like High Mix – Low Volume production can be helpful.

Challenge 2: Factory Space and Ceiling Height Restrictions

With the scarcity of land in urban areas, more machining facilities are located in high-rise buildings. Such factories face space limitations due to both the available floor space and the height of the ceilings. 

This is further complicated by the need to lift machines and equipment from ground level to the second or third floors or even higher levels. Unfortunately, this can be expensive, often requiring two cranes. Passage may also be impeded by walls blocking access to the factory. Breaking down these walls to access the factory requires approval and subsequent rebuilding.

To address these challenges, an integrated CNC machine set-up with multiple smaller work pieces can be a viable solution.

Challenge 3: Limited Power and Air Supply

When a factory has more machining centres, it requires more air, which means expensive air compressors with higher capacity must be purchased and placed near the machines. Additionally, energy costs have increased significantly since Covid-19. If there is a limitation in power and air supply, it can be very costly to increase the existing factory’s power supply level.

However, if a factory uses fewer machines, it can reduce its investment and overhead costs. To address these challenges, consider a CNC machining set-up that can cater to more machining hours while using limited energy consumption.

Challenge 4: Manpower Constraints

There is a global phenomenon of a shortage of available manpower, which has also affected companies in Asia and Singapore. Due to various reasons, such as constraints on recruitment and lack of experience for specific jobs, local manpower is not sufficiently available. This shortage has led to rising costs for companies.

To address this challenge, consider implementing flexible CNC automation systems that can reduce the need for manpower.

Solutions: Flexible Universal CNC Machines with Automation Systems 

The best way to improve manufacturing productivity and reduce human labour is to invest in flexible and universal CNC machines with effective and cost-efficient automation systems. 

An example of such universal CNC machines is the Hwacheon 5-Axis Machining Center D2-5AX. You may also consider the bigger D3-5AX with AWC 20 (Automatic Workpiece Changer) that allows for multiple and individual work setup stations. 

With a workpiece capacity of multiple parts, which can be of the same kind or a mix of different parts, you can “mix-and-match” your CNC automation system to suit your unique shopfloor needs. Such systems are available in 8, 20 or even 40 station capacities. Note that the size of the workpiece magazine selected should be based on your estimated parts cycle times. 

The number of parts loaded into the system as well as the cycle time for each individual part will define your CNC machine’s ability to work without human assistance. Typically, a 4-to-8-hour coverage is recommended to finish all parts loaded into the AWC magazine.

By integrating the Hwacheon 5-Axis Machining Center D2-5AX or D3-5AX with AWC 8, 20 or 40, manufacturing cycle times can be improved, resulting in shorter delivery schedules, ability to accept more orders, increased business volume and profit.

Other CNC machines with automation combinations include VESTA-660 / 1000+ with AWC (Automatic Workpiece Changer), VESTA 1300, M3-5AX, SIRIUS UM+ / UL+ with MPS (Multi Pallet System), CUTEX 180 series and Hi-TECH 230 series with Gantry System GR5 or GR10.

Yet another solution to improving manufacturing and logistics accuracy is to use robots. Robots can be added to any type of CNC machine, whether it’s a milling machine or a lathe/turning centre. However, whether robots are suitable depends on various factors, such as the shape, size, and weight of the parts to be produced, as well as the number of parts required. Note that robots are usually not suitable for “High Mix – Low Volume” production runs.

CNC machine automation provides numerous benefits to manufacturing companies. By automating your operations, your factory can achieve improved part accuracy, faster lead times, reduced setup times, shorter cycle times, lower costs per part, and a more efficient use of floor space and production time. 

Additionally, with unattended operation and better monitoring systems, factories can minimise manpower costs and improve machine utilisation, leading to increased productivity and profitability. Automating CNC machines further helps to increase safety in the workplace, as it eliminates the need for manual handling of heavy workpieces. 

Get started by asking yourself the big question – what and how to automate effectively?  Contact us if you would like to discuss possibilities or answer any queries. 

Your Questions About Large Size 5-Axis Machining Center SIRIUS-3000, Answered

#1 How fast?

SIRIUS-3000 5AX has the capabilities to machine complex shaped components and multiple processes much faster with the simultaneous 5-axial machining method and the 3+2 or 4+1-axial machining method in a single setting.

It adopts a high speed and high precision universal head with direct drive motors developed by Hwacheon, which facilitates quality product production even under prolonged machining.

The maximum feed and rapid rates for X / Y / Z axes at 60 / 60 / 45 m/min provides high speed machining which improve production efficiency and minimize cutting time drastically. 

The faster a machine needs to perform in all axes, the more rigid should be the mechanical structure of the machine. 

SIRIUS-3000 5AX is designed and manufactured with a stable gantry machine structure, rigid LM guide for X, Y and Z axis, twin ball screws on Z-Axis and application of glass scale feedback for all axes. Its NEW drive system comprises of linear motors in X and Y axis. These features offer unparalleled high speed and high precision performance required in today’s 5-Axis machining.

#2 How precise?

SIRIUS-3000 5AX is equipped with a powerful spindle, standard with HSK-A63 tooling system, maximum spindle speed 24,000rpm, 69Kw power and 126Nm torque. 

The powerful spindle uses an unique OIL-JET Lubrication System with high quality ceramic bearings. Fresh oil is being temperature-controlled injected onto the bearings and returned to the chiller unit, filtered and reused again. Creating a stable and constant temperature environment for bearings, resulting in maximum accuracy. The built-in motor spindle, designed and made in-house by Hwacheon, provides highest precision even during the longest cycle times. 

Further improved surface quality (Ra 0.8um) is made possible by 5-axis simultaneous machining with R-type end mill.

The low-cantered machine design further enhances the static stability and accuracy of SIRIUS-3000 5AX. Supported by gantry type structure, they provide best rigidity and optimum dynamic, vibrations are avoided or kept at a bare minimum. The workpiece weight does not influence the machine dynamic as it is static and not moving. 

Additionally, the machining center is integrated with 5-Axis software technology developed by Hwacheon. These functions contribute to high performance in surface quality, all in a single set up at maximum possible cutting speed and precision, to achieve the necessary tight tolerance and on time production schedules.

#3 How flexible?

The large table offers the flexibility to produce mid to large size mold & die and various precision parts.

• Table size : 3,500mm x 3,000mm
• T Slot (W x P) : 22mm x 200mm (18ea)
• Maximum loading capacity : 20,000 kg

Additional flexibility is realized by having its standard-fitted Automatic Tool Changer which enable prompt machining of parts that require many tools. 

With a capacity of up to 90 tools, the Automatic Tool Changer eliminates the need to switch tools, providing high productivity when running multiple complex parts.

#4 What are the industry applications?

Apart from machining large size precision molds, SIRIUS-3000 5AX is ideal for creating mid to large size complex and contoured parts required in the aerospace, automotive, oil & gas, energy and components for heavy industries, where precision and intricacy are often the key criteria.  

Application Example: Automobile Press Mold

#5 What is the price?

5-Axis Machining Centers are often seen as expensive and high investment. Higher quality 5-Axis Machining Centers may cost more. However, they can achieve extremely high accuracy and tight tolerances, and increase your business opportunities in the competitive CNC machining market. 

Pricing is mainly dependent on the base machine, options and systems selected as well as how and where the machine is manufactured. Like any other products, the term “you get what you pay for” is highly relevant. 

SIRIUS-3000 5AX is designed and manufactured by Hwacheon in South Korea. Built with top-notch quality and precision, extreme durability and through the use of premium raw materials and top-grade casting technologies. It provides good overall mechanics and are capable to deliver long-term accuracy and stability.

#6 What other useful features?

The performance of a 5-Axis Machining Center is typically gauged on its speed, precision and flexibility.   

The SIRIUS-3000 5AX is an new enhanced version and a big step up from the current proven SIRIUS-2500 5AX, which is known to provide highest performance at very competitive prices. 

SIRIUS-3000 5AX is built with the latest engineering and manufacturing techniques for either high precision large size Mold & Die or to achieve higher accuracy for specific large parts.

The 5-Axis Machining Center is equipped with Hwacheon’s proprietary technologies such as precision enhancement software and productivity enhancement software (HECC, HTLD, HTDC, HRCC and Optima) to ensure optimized machine performance. 

Additional features such as machine monitoring and remote diagnostics are also available.

#7 How to buy the right 5-Axis Machining Center?

First and foremost, you need to have a clear assessment of the projects you want to take in. 

Performing an assessment on the sizes and complexity of parts, materials to be machined, level of precision, cutting tools, floor space, etc allows you to select the most efficient and cost-effective 5-Axis Machining Center, and the required options and systems. 

There are also other important factors to consider. Read more about choosing the right CNC machine tool for your factory here. 

It’s time to give SIRIUS-3000 5AX a deeper look. 

Watch video to view more features about SIRIUS-3000 5AX. 

Alongside trends in large size intricate and complex components, 5-Axis machining is seen as the most practical manufacturing method. 

With extensive experience in manufacturing large size CNC machines, Hwacheon has the expertise to custom make Large Size 5-Axis Machining Center according to your specific needs. You can be assured of high standard of quality through our rigorous testing and be supported by experienced engineers who understand your applications. 

Contact us for a discussion, a catalogue or to request for a price estimate.

Big CNC Machine Tools for Big Machining

CNC machines are ideal tools for producing various components with precision and accuracy. However, depending on the size and type of the CNC machines, they may have limitations in producing large, long and heavy components. Common challenges faced are that the parts are too heavy, too large or too long. 

Large size machine tools involved huge investments and resources. The question is, which large size CNC machine is suitable for your production success?

Hwacheon Heavy Duty CNC Lathe MEGA II-260

Hwacheon’s heavy duty flatbed Horizontal CNC Lathes MEGA II-260 is specifically designed for machining of large parts and long and complex shaft type applications such as main shafts and large pipes. 

With a weight of over 110 ton, the extraordinary machine structure and design provides rigid turning which require application for OD & ID operations. 

MEGA II-260 is capable of handling components up to 2.2m in diameter and 17m in length. It features a distance available between centers from 6m to 17m and a maximum weight capacity between centers of 25 ton at 130 rpm. Optionally a 40 ton version is available too.

MEGA II-260 is one of Hwacheon’s Heavy Duty CNC Lathes MEGA Series and MEGA II Series. These MEGA machines have been installed and in operation globally since 1998. 

Today the modern design of the MEGA Series / MEGA II Series are further enhanced and specifically designed to market and customers’ feedbacks and application needs.

• MEGA Series – MEGA-72 / 100 / 110 / 130
• MEGA II Series – MEGA II-160 / 200 / 260

Applications of CNC Lathes MEGA Series / MEGA II Series

• Aerostructure
• Oil & Gas
• Machinery
• Mining
• Power Plant
• Shipbuilding
• Windmill & New Energy
• Other Large and Heavy Precision Parts

7 Key Features of MEGA Series & MEGA II Series

1. High rigid flatbed structure, made in house by Hwacheon Foundry, provide optimum rigidity and performance.
2. Main frame structure supported by high-precision thrust & cylindrical roller bearing.
3. Turcite type bed slide way maintain high rigidity during prolonged cutting.
4. Spindle construction, designed and made by Hwacheon, allows stable operation and machining at high speed and low speed with high torque process by gear transmission.
5. Rib-frame head stock minimize thermal deformation while supporting spindle with high precision roller bearings.
6. High precision ball screw system for X- and Z-Axis enables safe and precise operation without twisting or sagging of the ball screw (applied by LM guide to support long ball screw).
7. Large-sized tailstock designed to provide best rigidity with 3 points support, minimized thermal deformation by forced lubrication and cooling system.

Take a look at the manufacturing of heavy-duty flatbed Horizontal CNC Lathes in our facilities in South Korea. View video here:

Why Use Hwacheon

CNC machining is a key necessity in today’s manufacturing sector. Machined components must conform to the design specifications and industry standards to function accurately and efficiently. 

Hwacheon fully understand the importance of producing quality parts in a timely manner and using high quality components in our machine tool manufacturing. Critical components are manufactured in-house which enable us to have complete control during the manufacturing process of our CNC machines. 

Selecting the right size and the right type of CNC machine is crucial to deploy its full benefits for your production success. And it need not be a tedious process. 

Hwacheon has the expertise and experience to recommend suitable CNC machines and customised solutions to your exact requirements, including working alongside with your team on the facility preparation for delivery, installation, commissioning and training. 

To learn more about the different types of large and heavy-duty CNC machines available for large and heavy components like shafts and pipes, and to choose the best options and systems available, feel free to reach out to us here!

In this article, you will learn all about the fascinating world of foundries and metal casting. We will cover the following topics:

• Definition of a Foundry
• Raw Materials used in Casting
• Machines Deployed in Casting
• Casting Process
• Casting Technology Best Practices
• Finished Products of Foundries
• Hwacheon’s Investment in Foundry and Casting Technology

Ready to explore the world of foundries and metal casting? Put on your heat protecting gear, don your helmets and let’s step inside!

Definition of a Foundry

A foundry is a custom-built facility that produce metal castings. This is done by melting metals at very high heat into liquid in a furnace, pouring the molten metal into molds, followed by a controlled cooling process, removal of the casted part from excess material after the metal solidifies, and a final cooling step.

Note that temperatures of the melted metals can reach up to 1500°C (2700°F) or even higher, depending on the types of material to be melted.

What Are the Raw Materials Used in a Foundry?

There are many different types of metals (or mixtures of alloys) used as casting materials. They may include metals like iron, stainless steel, carbon steel, or alloys made with copper, nickel, and aluminium.

At Hwacheon Machine Tools, we produce a mixture of different casting materials such as Ductile Cast Iron, Nodular Cast Iron, Gray Cast Iron, High Silicon Cast Iron, Low Thermal Expansive Cast Iron, and Special Cast Iron.

To reduce our environmental impact, up to 55 percent of the raw material used may be scrap metal. The remaining materials would be pig iron (20 percent) and recovery iron (25 percent).

Sand is commonly used to build mold frames in casting (sand casting). In our case, we use sand from Saudi Arabia, which is known to be superior in casting processes.

What Are the Machines and Equipment Used in Casting?

Various machines and systems are used to optimize a foundry. These may include melting equipment, molding making machines (which can be CNC machine tools), sand processing equipment, heat treatment equipment, as well as testing and inspection equipment.

For the new Hwacheon Foundry, we use the following top-of-the-line machines and equipment (from South Korea, USA and UK):

• Melting Equipment: Electric furnaces that are 3 tonne and 6 tonne each (Inductotherm – USA)
• Mold Making Machines: Hwacheon Machine Tools like the SIRIUS-2500 5AX
• Sand Processing Equipment: OMEGA (UK)
• Heat Treatment Equipment: 10 Tonne Annealing Treatment Equipment (South Korea)
• Testing and Inspection Equipment: Spectro Meter, Universal Testing Machine, Ro-Tap Shaker, Brinell Hardness Test Machine, and Metallograph

As you can see, the process of producing metal castings in a foundry requires significant investment in machines and equipment!

What is the Process of Metal Casting Like?

Now that we’ve got the raw materials and the needed machines settled, the next step involves the actual production process of casting itself.

Hwacheon Foundry deploys the following processes to produce metal castings.

#1 Melting

Liquid casting material is melted up to temperatures of 1,380°C to 1,420°C. The material may comprise a mix of scrap metal (55%) + pig iron (20%) + recovery scrap (25%). Other combinations of raw materials may also be used depending on the casting to be made.

#2 Mold Creation and Machining

The pattern is created, either machined by special wood mold making machines or, in our case by Hwacheon CNC Machining Centres. Sand is then packed around the pattern, forming a sand mold which is a replica of the external shape of the later casting. Hwacheon uses the Furan sand casting method due to its key advantage in producing diverse sizes and shapes.

#3 Prepare and Assemble Mold

The sand mold is prepared and assembled for the molten metal to be poured into.

#4 Pouring Molten Metal into Mold

At the filling stations, the liquid metal is poured into the mold.

#5 Cooling

After filling, the extremely hot mold frames (you can literally see flames shooting out!) are put on a slow and long cooling circle.

#6 Remove Casting from Mold

When the molten metal in the mold is cooled and solidified, the final shape of the casting is formed. The sand mold can be “broken” or “shake out” to retrieve the actual casting part.

#7 Trim Excess from Casting

Excess materials stuck to the surface of the casting are removed by thorough cleaning and deburring, followed by painting (using protection paint).

#8 Finishing of Final Products

Towards the last step, quality checks and tests are made. A composition analysis using a Spectro Meter is done (to check material mix), followed by a material test using a Universal Testing Machine and Brinell Hardness Test Machine, before ending with a microstructure test (a Metallograph is used).

#9 Storage/Delivery

After the product is finished, it is important to keep the castings properly stored in cool conditions in a separate area.

Best Practices in Casting Technology

To ensure that you get the best results in casting, it is important to use the latest technology. Let us share some of the best practices that we adopt here at Hwacheon Foundry.

#1 Adopt Sand-Casting Technology

Hwacheon uses the sand casting method rather than other materials like wax, plaster, or die-cast. This Is due to the following reasons:

• Sand casting allows you to achieve high rigid casting and surface stability with a small amount of binder.
• Kneaded sand is highly liquid, hence reducing manufacturing time because no firing process is required.
• The high heat resistance and low gas generation in sand casting results in fewer casting defects.
• You do not need a separate process for removing casting from mold — just hit it to break it!
• You can recover more than 95% of the sand used — this makes sand both resource saving and pollution protecting.
• The molding process of sand does not require highly skilled operators.
• Sand casting makes it feasible for mass production as well as large-sized casting.

#2 Manage the Entire Process

Beyond this, Hwacheon also adopts these other best practices in casting technology:

First, we focus on achieving high quality throughout the entire automation process.

Second, we adopt strict Quality Control (QC) management, making sure that only high-quality materials (scrap, pig iron) are used. We also adopt controlled measurements to achieve precise melting temperatures for the materials.

Third, we ensure that the temperature is controlled through looking at the dissolution temperature and pouring temperature.

Fourth, we adopt leading edge cooling control measures. These include an auto cooling tunnel which prevents cracks by slowing the cooling process – an important consideration as rapid cooling will result in tensions in the material as well as potential cracks. Typically, the cooling time for casting is more than 24 hours. This may hit 48 hours for castings that weigh over 3 tonnes.

Fifth, we use a customised heat treatment facility, ensuring that Hwacheon products are suitable for high speed and high precision machines.

#3 Be Mindful of the Minor Details

Wait, there is more. To ensure high quality sand-casting, you should also take care of the following.

Start by carefully choose the best sand quality. This should include:

• Particle size control
• Sand composition management
• Dust control

Next, think about the melting quality of your materials:

• Scrap quality: No stain, no Mn (Manganese)
• Pig iron quality: Must have low Mn (Manganese), P (Phosphorus), and Ti (Titanium)
• Dose control: Measure all materials in the exact amounts
• Temperature control: Keep to the right degree for melting, and pouring

Finally, consider the cooling quality of your materials. Remember that rapid cooling can introduce cracks and fractures in your castings!

What are the Finished Products of Foundries?

Last, but certainly not least, what are the finished products made in foundries?

For Hwacheon Foundry, about 30 percent of our finished products are used for manufacturing Hwacheon’s CNC Machine Tools. These include casting for machine beds, columns, saddles, bed frames, spindle housing and other components.

Our foundry also supplies components to reputable companies around the world. They include:

• Machinery and its parts
• Robot arms and bodies
• Railway transportation parts
• Semiconductor equipment components (low heat expansion casting)
• Corrosion resistant components (e.g. HSCI, stainless pickling electrode plates, cathodic protection electrodes)
• Ship engine parts
• Solar energy system components,
• Many other machinery parts

Why Hwacheon Invests in The Foundry Business

Hwacheon takes pride in having our own foundry due to the importance of casting used in all industries.

Our late founder and honorary chairman, Mr Kwon Seung Gwan himself, started work as an apprentice mold maker in a foundry in his teens. His grit, determination and attention to quality resulted in taking over the ownership of the foundry in 1945, back when Hwacheon first started.

Casting material forms the very basic parts in all of industries. The process of casting continually expands with shifts in technology. Our foundry isn’t just Hwacheon Group’s birth right — it also lays the foundation of future industries.

The advantages of using Hwacheon castings on our CNC machines (based on customers’ feedback) include:

• Ability to achieve high rigidity, performance, speed and precision
• No ageing deformation while maintaining high speed and precision
• High cutting performance
• Durability and longevity
• Ability to keep up to our delivery schedule

Hwacheon’s New 21,000 sqm Foundry

Hwacheon has recently invested USD28.7 million in a state-of-the-art facility in the Daema Industrial Zone.

This new facility occupies a total land size of 73,000 sqm, with a built-up factory space of 21,000 sqm, making it one of the largest foundries of its kind in South Korea. Starting production on 22 December 2021, our foundry currently employs 120 employees, and runs at a capacity of about 1,000 tonnes per month.

You may be keen to know that the heaviest part that we can cast is a staggering 8 tonnes! Our total capacity for the facility is 12,000 tonnes per year at this point.

Hwacheon decided shortly before the Covid-19 pandemic on this new investment so that we can develop a permanent and reliable raw material business for the future. This is part of Hwacheon’s unique advantage.

Take a look at Hwacheon’s new foundry! Watch video here:

Our Future Plans in Casting Manufacturing

“Hwacheon understands the goals and objectives of casting components in manufacturing because many of our operations are just like yours” – President Kim Ki Tae

President Kim, a pioneer in the metalworking industry, is the key person transforming Hwacheon Foundry to what it is today. He has worn multiple hats during his 35-year tenure with Hwacheon – in machine tools manufacturing, R&D, as well as leadership of the new Hwacheon Foundry.

A firm believer in having our own foundry, President Kim is committed to continuing to deepen our expertise and knowledge in casting manufacturing.

Hwacheon has invested and will continue to invest in production facilities that combine production know-how (accumulated over decades of experience) with the latest casting technology and automation system.

Hwacheon will further nurture our talents through continuous industry-university cooperation and technical cooperation projects with both universities and institutes. Our human resources are the company’s most important assets — hence, we will continually cultivate excellent skilled workers.

Contact us for more information on our Foundry and our range of CNC Machines.

One of the misleading calculations made by many manufacturers is this: Invest in a low-priced CNC machine tool to reduce their production costs. After all, the price of a CNC machining centre or turning centre can be tens of thousands, hundreds of thousands or even going into the millions of dollars.

Sadly, such thinking is rather common among manufacturers. It fails to consider the total costs of running CNC machining operation in any machine shop. Often, the price of the machine tool is just a small component of the real cost of CNC machining.

In this article, you will learn what the major components of CNC machining costs are, consider the hidden costs that you may miss out to think about, and uncover ways to save money on your CNC machining operations.

10 Main Components of CNC Machining Cost

Before we dive into the various components of CNC machining cost, we need to look at a typical machining process at a manufacturer that does part fabrication for its customers. 

Often, the manufacturer (our clients) receives an enquiry to quote an order to fabricate. To fulfil the job, the manufacturer needs to consider multiple factors in order to accurately work out his total machining costs. 

Without knowing exactly what these machining cost components are, he may under-quote (resulting in a loss) or over-quote (which may result in his prospect searching for alternative suppliers).

So, what are these major factors? Let us look at them below.

#1 Part Design and Complexity

First, you need to consider how complicated the part to be made would be. Indeed, part design and geometry can play a significant role in machining cost. 

The more complex a part is, the more expensive it can be to manufacture that part. This is due to various factors such as the need for a more advanced machine, the time to fabricate each part, the possible need for multiple set-ups and processes, as well as the need for more stringent quality control due to tight tolerances.

Non-standard parts with thin walls, deep cavities, irregular hold sizes, or high surface qualities may also lead to higher cost per part made.

#2 Volume of Production

This is one of the most universally understood factor in machining costs. The larger the volume of the produced part, the lower the cost-per-part would be. 

A major challenge here is the move towards high mix – low volume production, which makes it necessary for machine shops to make a large variety of products in small batches. Such practices will certainly add to machining costs.

#3 Material Types

Different materials have different costs. A standard block of stainless steel will certainly cost less than a more advanced alloy like Inconel on a price per block basis. 

Some of the standard materials used in machining include Aluminium, Stainless Steel, Brass, or even Titanium alloy. Depending on the material chosen, you will experience different degrees of machinability and cost.

#4 CNC Machine Related Costs

The efficiency, flexibility, precision, and durability of your CNC machine tool plays a crucial role in machining costs. Here, you should consider the following components of machine-related costs:

• Cost of the machine tool itself
• Estimated cost per year for spares (reflecting on quality made / used in that machine)
• Estimated number of hours the machine can operate in a year
• Labour costs needed to operate the machine
• Types of cutting tools you can use with your machine
• Surface finishes that can be achieved
• Availability of automation systems (learn how Hwacheon does it here) 
• Ability to machine across multiple axes
• Time needed to set-up, manage and handle post-processing of parts
• Maintenance and repair costs needed (learn how to adopt preventive maintenance here)

As you can see, there are many machine-related costs, well beyond the initial price of the machine itself.

#6 Programming Cost

Programming is often expensive because of the need for expert manpower to design and digitalise the required part as well as the level of CAD / CAM required. 

First, the product needs to be given to a designer which made this into a CAD (Computer Aided Design) file. Next, the manufacturing engineer would need to check that the design can be efficiently produced and make suggestions to improve its machinability. Finally, a programmer is required to turn the CAD files into a CAM file, which will then be fed into the CNC machine.

(This also relates to part complexity—the more intricate the design, the more manhours needed to design and programme it.)

#7 Set-up, Changeover and Processing Cost

In the world of manufacturing, time is money. The more time you take to produce a part, the more costly your machining process would be.

Set-up costs often involves a Production Engineer, who will have to make sure that everything is ready before the first batch of parts can be produced. He will need to plan for the production workflow, the materials needed, setting-up of the machine, as well as how to clamp the material / part and cater to changeovers needed (if any), and post-processing of the CAD file with a CAM.

#8 Quality Costs

Also known as the Cost of Quality (COQ) which is more accurately understood as the cost of poor quality, quality costs are associated with preventing, detecting and addressing product issues related to quality.

In a machining environment, such costs may include:

• Inspection costs needed to appraise a produced part for quality issues
• Test equipment required to check on quality and consistency of parts
• Internal failure costs when defective products are produced — these must be scrapped or reworked
• External failure costs which occur when a defective product is delivered to the client. These can be especially costly should there be product recalls, warranty claims, field service, and even customer lawsuits!

#9 Opportunity Costs

These are often invisible to the manufacturer, but they can make a significant difference to the profitability of your machining operations.

Opportunity costs may include any of the following:

• Downtime: The more downtime due to disruption to your manufacturing, the more money you will lose
• Disruptions: These are largely due to either human errors or equipment failure, and may even be as major as machine tool crashes.
• Capacity: Depending on your manufacturing set-up, you may be unable to take on additional jobs due to the capacity of your machining operations
• Competency: This could be another factor leading to missed opportunities, and may include the lack of the right equipment, or skilled manpower

#10 Utility, Space, Labour, Training and Other Costs

Finally, you need to consider the cost of electricity, water, waste disposal, cleaning, space, and other ongoing operating costs. These may be considerable if you are running a 24/7 operation for your machine shop. 

Let’s also not forget the need to cater to shifts in manpower, as well as the number of operators needed for each process. Depending on the proficiency and skill level of your workforce, you need to also cater to their training and upskilling needs.

Reduce Your CNC Machining Costs with Hwacheon

Keen to know how you can reduce your machining costs?

Consider investing in Hwacheon’s meticulously designed and robustly-built machine tools.

As one of the first companies in the world to deploy smart operating systems and automation software for our CNC machine tools, we take great pains to produce high quality machines that are engineered to reduce your total machining costs. The basis for our approach is “Mechanical Stability”.

These include ensuring top-notch quality and precision, extreme durability through the use of premium raw materials and top-grade casting technologies, and utmost precision through years of craftsmanship.

Our Automation Systems are also designed to provide total machining solutions. Through the use of automation, productivity-enhancing software, and multi-configurable settings, they can significantly reduce your set-up time for multiple operations and optimize your productivity.

Contact us for CNC machine recommendations, specifications or for price estimates 📧 enquiry@hwacheon.com.sg