Counter Pressure Casting Machines
for fully automated production
and multiple parts capability, which is suit to all aluminum casting parts for automobiles.
Who "CPC Machines" is
In a business where reliability and efficiency are paramount, the CPC Group is proud to have more than 100 years combined experience in the manufacturing of over 1,000 state-of-the-art casting machines. We provide our customers with the expertise of 500 highly skilled engineers, technicians and machinists who create, build and maintain the best in mass production technology and machinery operating around the world.
Counter pressure technology is being used by nearly every major automobile manufacturer in the world for chassis components and those that aren’t, soon will be.
Because of the many advantages CPC technology provides, it is also the number one choice for any aluminum castings where high strength, reliability and cost are factors. We have many customers in the automotive, motorcycle, marine and electrical industries that lead the world in production and require the superior quality products only CPC can supply.
CPC EUROPE, CPC USA & CPC ASIA
CPC Europe (Group headquarters), CPC USA and CPC Asia form the principle network of worldwide sales, service and operations. With locations around the globe, we can ensure our customers receive fast and reliable service anywhere in the world.
ILINDEN LTD
Ilinden Ltd. is a key member and the principal equipment manufacturing unit of the CPC Group. With decades of experience in the production of counter pressure casting, low pressure casting and gravity casting machines, as well as supporting equipment, Ilinden Ltd. has become a global leader in the industry with 98 percent of its business export.
Ilinden’s mold division is a one-stop shop for design, engineering, testing and development of counter pressure technology. A market specialist in mold manufacturing, Ilinden delivers the highest quality molds for CPC machines as well as high and low pressure dies and tooling.
CPC-CERAMICS
The CPC Group’s Ceramics division has been developing Aluminum Titanate (AlTi) products for the foundry industry for over 20 years, including many used in our counter and low pressure casting machines. We can meet the needs of the most demanding customers by offering quality, selection and value for their investment.
Counter Pressure Casting Technology
For the past 15 years, CPC Group has been developing its technology, casting machinery and resources to be specifically tailored to the automotive chassis components market. With automotive manufacturers looking to reduce chassis weight, aluminum has been the material many are turning to. Aluminum replacement parts can achieve up to a 50 percent weight reduction over other conventional materials. The challenge has been to find an economical and dependable means of production in an industry where safety and reliability are critical. Counter Pressure Casting (CPC) is an innovative process that combines economy with highly reliable mass production technology to manufacture superior quality aluminum parts.
Process
There are many problems to watch for in other conventional aluminum casting processes such as low pressure, vacuum pressure, sand and squeeze casting. There is the chance of turbulent metal flow, the introduction of gases during filling and solidification porosity which contribute to the weakening of the casting’s structural integrity. These problems are reduced and controlled by CPC to provide castings of superior strength and reliability.
CPC uses two separate pressure chambers. The process begins by equally pressurizing both the furnace and the mold chambers. The pressure in the furnace is increased while the pressure in the mold chamber is released. (The pressure differential is usually between 300 to 1,000 mbar.) This allows the melt to rise in the filling tube(s) with constant counter pressure on the melt’s surface. The filling process is non-turbulent and allows for better control and uniformity. The continuous counter pressure on the casting chamber also prevents the introduction of gases that normally occurs during filling in other processes.
Solidification is controlled by using air or water for directional cooling. At the beginning of casting solidification, increased pressure is applied in the furnace chamber to achieve maximum feeding to areas prone to shrinkage. This ensures dimensional repeatability and increases the casting’s metal density. The constant pressure suppresses gases that would normally cause defects in the casting. Up to 6 bar of pressure may be applied without any risks to safety by using the closed-chamber system. When the casting has cooled, the pressure is quickly released in both chambers and the process is repeated.
Results
Defects in casting reduce both its strength and structural integrity. With CPC’s ability to control metal flow in a tranquil fashion, a more uniform microstructure is attained. Using counter pressure during the entire process helps prevent the introduction of gases and porosity.
Another advantage is lower variability in elongation and strength in the squeeze, vacuum pressure and sand casting. CPC can achieve elongation of 14 percent. Other processes show nearly twice that variability in their results.
Economic Benefits
In addition to its technical advantages, CPC has a number of economic benefits:
- The initial investment cost is extremely low relative to its exceptional return.
- The short learning curve and low complexity make the process easy to integrate into any existing production.
- An impressive yield of 95 percent or more is achieved by utilizing the most of the material.
- Mass production has reliable results, and with the capability of up to 10 castings per cycle, CPC is the most cost-effective solution.
Process Step
Step1
- Mold chamber closes
- Casting cycle begins
Step2
- Furnace and Mold chambers are pressurized equally
Step3
- Pressure is increased in the Furnace chamber
- Melt begins to fill the mold cavity
- Counter Pressure is continually applied in the mold chamber
- Precise control of the filling process
- Smooth, non-turbulent/quiet filling
- Closed melt front due to counter pressure action prevents pore gas entry
- Uniform metal flow for uniform microstructure
Step4
- A shell is formed
- The parts are filled and the inlet tube continues to feed under pressure
- Boost increased furnace pressure
- Directional air/water cooling to control the solidification process
- Continuous counterpressure
- Suppression of gas causing porosity
- Constant pressure, so up to 6 bar pressure to improve delivery to areas that tend to contract
- Longer contact time between die and solidified melt before shrinkage gap occurs
Step5
- Pressure equalization (ΔP=0)
- Return to melting furnace
- Feed completed
- Continue solidification as needed
- Keeping the gas in a dissolved state suppresses it and virtually eliminates porosity.
Step6
- Casting solidification
- Release of pressure
- Cast eject
- Total cycle 136-210 seconds
Application
CPC is ideal for products that require a high strength-to-stress ratio to ensure safety and reliability. A perfect application would be chassis parts where high mechanical properties and ductility are needed in a very stable repeatable process, such as:
- Front and rear steering knuckles/spindles
- Upper and lower control arms
- Subframes
- Front & Rear Crossmembers
- Structural brackets
- Yokes
- Shock towers
CPC is able to maintain the mechanical properties and ductility of the part, showing little variation even in mass production. This innovative technology, combined with its efficient and highly productive casting machinery, make it the best choice for aluminium chassis parts production. Major automobile manufacturers worldwide are taking advantage of CPC’s tried and proven process.
Products
CPC proposes below products to customers, which are developed by applying CPC’s own technologies.
- Counter pressure casting system and machine
- Counter pressure mold/die
- Tilt injection machine
- Aluminum degassing system
- Melt transfer/shuttle system
- Other supporting equipment
- Ceramic products
Machines
CPC 1300 C12
Overview
Counter Pressure Casting (CPC) machines have been developed to utilize the counter pressure casting process. With more than 40 years of experience using counter pressure, we are able to exceed our customers’ requirements for efficient production of aluminum castings in permanent, sand or combined molds. Our equipment produces castings that exceed the highest requirements for mechanical properties, structural strength density, surface smoothness and dimensional accuracy. Each machine is designed to control all parameters of the CPC process while providing simple and reliable operation with minimum maintenance.
With the ability to operate in counter pressure or low pressure mode, the CPC 1303 is the most versatile machine available on the market.
Machine Construction
The 1300 series is designed on a simple and reliable concept. The rugged, vertical four hard chrome plated steel tie bars are attached to four main platens. The top and bottom plates are fixed with movable and intermediate platens guided by the tie bars installed between them. These two plates control the main movements and operations of the machine.
CPC 1500 C64
Overview
The CPC 1500 C64 was developed exclusively for high strength structural parts production. With extremely fast cycle times, revolutionary counter pressure technology, and the ability to cast up to four parts at once, this is one of the most advanced pieces of equipment CPC offers. Our customers are using this technology to cast high strength structural critical parts for nearly every major automobile manufacturer around the world.
Feature
- Cast up-to 4 Cavities or 8 Parts Per Cycle
- 64 Air/Water Cooling Lines
- Large Casting Capabilities
- 4 Fill Tube Configurations
Machine Construction
The machine is designed on a simple and reliable concept. The rugged, vertical four hard chrome-plated steel tie bars are attached to four main platens. The top and bottom plates are fixed with movable and intermediate platens guided by the tie bars installed between them. These two plates control the main movements and operations of the machine
Ability to cast multiple parts during one cycle
To be successful in the OEM market today, you have to get maximum efficiency, as well as quality, from your equipment. Our machines allow you to fit up to four dies in the die chamber with the capability of casting multiple parts at one time. There is even the ability to change the flanges allowing for different numbers and configurations of riser tubes giving you optimal flexibility.
CPC 1600 C96
Overview
CPC developed the 1600 C96 casting machine for the ultimate in high strength chassis parts production. With the ability to produce up to 10 castings per cycle, minimal cycle times, and our revolutionary counter pressure technology, this is the most advanced combination of technology and equipment on the market today. It is the largest machine ever built by CPC and has surpassed the expectations of today’s OEM manufacturers. The CPC 1600 C96 is unmatched in the industry and provides our customers with production advantages on multiple levels they won’t find anywhere else.
Feature
- Cast up-to 6 Cavities or 12 Parts Per Cycle
- 96 Air/Water Cooling Lines
- Largest Casting Capabilities
- Multiple Fill Tube Configurations
Machine Construction
The machine is designed on the same principle that all of our foundry-proven machines have been built. With optimal heavy duty construction on our rugged, vertical four hard chrome-plated steel tie bar and movable plate design, the CPC 1600 gives you even more reliability in difficult foundry conditions.
Larger capabilities and even more castings per cycle
The CPC 1600 has higher productivity then any other chassis casting equipment on the market today. With its 96 air/water cooling lines, you can cast up to six cavities or 12 parts per cycle. The larger platen provides a broad range of capabilities including fitting up to six dies in the die chamber with the ability to cast multiple cavities per die at one time. There is even the ability to change the flanges allowing for different numbers and configurations of riser tubes giving you maximum flexibility.
CPC 1800 C128
Overview
Designed with versatility and efficiency in mind the CPC 1800 has the capability to cast 8 parts at once using 128 water/air cooling circuits. This is the most productive machine to date using our Counter Pressure Casting technology. The larger platen size allows for multiple mold and fill tube configurations with larger overall part dimensions. The CPC 1800 can be used for either 8 cavity production or complete subframes.
Feature
- New design
- 128 air/water/mixed cooling lines
- 8 Cavity
- 1200kg furnace
CPC 2000 C128
Overview
The CPC-2000 is the largest machine every built by the CPC group to accommodate the growing demand of complete Counter Pressure casted subframes. The expansive size allows for up to 2 subframes to be cast at once adding a new dimension to CPC capabilities. This ushers in a new era in efficient Aluminum subframe production. The 128 cooling lines and larger platen size also allows for 8 cavity production in this same machine.
Feature
- New design
- 128 air/water/mixed cooling lines
- 8 cavity
- Integrated quick change mold carts
- 1.2 ton furnace shuttle system
- Subframe casting
■Integrated Quick Mold Change cart
■Shuttle Line
Subframe Casting
■Subframe-One piece hollow casting
CPC New Machine Spec
CPC-1600
CPC-1800
CPC-2000
Utilities
SHUTTLE SYSTEM
The shuttle system is the CPC Group’s original design and invention. It has been revolutionary in the industry, increasing efficiency and production. We created the shuttle with the idea of developing an integrated casting solution (not just simple casting machines) that improves every step in the process of making a good casting. Everything starts with our shuttle system which includes integrated degassing, holding stations and mold changing operations ensuring every step of our counter pressure casting process is controlled with maximum efficiency. Our shuttles can handle operations for a line of up to eight machines. With over 15 years’ experience, CPC is unmatched worldwide in performance and reliability.
Operation
The major advantages of CPC’s shuttle system are the ability to bring the cleanest alloy possible to each machine and the safe and rapid exchange of empty holding furnaces with full ones. The holding furnaces are identical and are interchangeable with any machine on the line. After a holding furnace is filled, it is “shuttled” to the degassing unit and then directly to the machine that needs new alloy. The empty furnace is removed onto the shuttle and the full one inserted in its place. This process eliminates the chance of oxidation often caused by re-pouring the metal into a machine’s holding furnace after degassing. CPC’s shuttle system ensures our customers get the cleanest alloy possible.
INTEGRATED DEGASSING UNIT
Our degassing unit is fully integrated with our shuttle system. Once a holding furnace is filled with alloy, it is shuttled directly to the degassing station. Heating is controlled continuously during the process using our unique plug that automatically “plugs in” to the furnace. After degassing, the full holding furnace is shuttled directly to the designated machine and exchanged with the empty furnace.
Operation
The degassing unit is a molten metal treatment system for degassing and cleaning aluminum alloys. The unit operates on the rotor principle — a high-speed rotating rotor disperses inert gas (or nitrogen) into the molten aluminum alloy. The degassing process removes hydrogen gas, and non-metallic inclusions such as oxides, by dispersing inert gas bubbles through a rotary diffuser into the molten alloy.
The hydrogen in the melt diffuses into the inert gas bubbles and floats to the surface. At the same time, any non-metallic inclusions present are absorbed onto the rising gas bubbles and are also transported to the melt’s surface.
To remove inclusions most efficiently, it is essential to diffuse very fine bubbles, maximize the number of bubbles (increasing the chance for contact with impurities), and maintain gentle bubbling with minimum turbulence on the melt surface.
The advantages of our rotary degassing process are:
- Shorter treatment time – 3 to 10 times faster than other degassing methods
- Higher quality alloy after treatment
- Less metal loss – 30 to 70 percent less dross than other methods
- Low operating costs
- Easy operation and maintenance
CPC’s specially designed degassing unit has been proven to provide our customers with the purist aluminum alloy possible.
QUICK MOLD CHANGE CARTS
The quick mold change carts are another great system CPC developed to make the process of changing molds simple and fast. A mold can be changed in less than ten minutes in automotive wheel production with CPC’s special quick connecting cooling lines.
Operation
Two mold change carts are pulled onto the shuttle system. One holds a preheated mold ready for operation while the other is vacant, ready to remove the existing mold. The empty cart is inserted into the machine’s mold cavity and the mold is lowered onto the cart. With the push of a button, the mold is released from the machine. The shuttle then positions the cart with the new preheated mold into the mold cavity. Again, with just the push of a button, the preheated mold is attached to the casting machine. The quick connect cooling lines are connected and casting can begin. What used to take up to an hour can now be done in just minutes.
INTEGRATED QUENCH TANK
Our fully automated quench tank is directly integrated with our casting machines extraction manipulator. Quenching after casting increases mechanical properties and cools the casting for easy handling. The quench tank system is easily integrated with any of today’s major robotics manufacturers.
Operation
Only one manipulator is needed per two machines to maximize space and initial investment. The manipulator begins by removing the casting from the machine’s retriever and lowering it onto the quenching platform. The platform lowers into the quench tank for a set amount of time. After quenching, the casting is retrieved by the manipulator and rotated 180 degrees to remove any excess water. Next the manipulator brings the casting to the operator for inspection. Upon approval, it is lowered onto a conveyor that runs under the working platform and removed to the next operation.
COOLING SYSTEM
Up to 96 cooling lines are available per machine to reduce the casting cycle time. We use water boosted cooling up to 10 bars with a reservoir ensuring constant pressure. Each cooling line is independent and can be controlled by time, temperature, or a combination of time and temperature.
We specially designed a flow meter rack that is easily accessible to the machine operator. This allows for the computer-controlled cooling flow to be monitored visually and mechanically.
Ninety-six cooling lines means 192 connections (one inlet and one outlet per line) have to disconnect and reconnect each time a die is changed. We created a die holder with an integrated manifold that automatically connects all 96 cooling lines when the die is operable.
※Number of cooling line will be optimised and proposed by based on the machine capacity
FURNACE
An electric crucible type holding furnace, complete with furnace cover lid, is located between the bottom and intermediate platens of the machine. Its proven and reliable design and electrical resistant heating elements provide the highest quality alloy over refractory reverb type furnaces.
A quick disconnect power connector is installed on the furnace and basic platen. This allows our specially designed shuttle system to change the furnaces, increasing production efficiency. In full open position, the furnace can be moved out of the machine on a shuttle cart for easy exchange, or, in a fixed position, for cleaning and filling.
※The capacity of the furnace will be optimised and proposed by based on the machine capacity
CASTING RETRIEVER
An automatic casting retriever transfers the ejected castings out of the working zone of the machine. Extraction may also be done by integration with any of the major robotics manufactured today. The casting retriever can also be safely stowed away as a backup retrieval system when robotics integration is done.
ADDITIONAL SAFETY EQUIPMENT / CONTROL SYSTEM
Light-weight curtains or electromechanical movable working platforms for protection in dangerous areas around the machines.
- Touch screen monitor
- Short learning curve
- Complete display of equipment status
- 6-point casting curve adjustment
- Individual control of each of the 96 cooling circuits
- Saves 999 casting recipes
- Save casting data for one month
- Online network for data extraction and service connection
CPC Ceramics
The CPC Group’s Ceramics division has been developing Aluminum Titanate (AlTi) products for the foundry industry for over 20 years, including many used in our counter and low pressure casting machines. We can meet the needs of the most demanding customers by offering quality, selection and value for their investment.
Products
- AlTi Riser tubes
- AlTi Bushings
- Dosing Tubes
- Degassing Baffle Plates
- Degassing Rotor & Shafts
- Thermocouples
- Furnace Bricks
Found Four Co., Ltd.
Toshin Bldg. 4-17 Kaigandori, Naka-ku, Yokohama, 231-0002 Japan
+81-45-222-6420 : Phone / +81-45-222-6407 : Fax