The TOCA Ductile Iron Foundry in Dingzou Foundry entrance and office Foundry buildings Ingot shed (with correct material sign)
Documenting the Foundry Process A view of the mold shop is on the right TOCA uses an hybrid casting technique, employing thin shell resin sand molds and resin sand cores to cast parts Shells and cores are created using patterns that are filled, pressed into the mold shape and then cured in a heating process on the press shown on the right 4 cavity tools make the 2 haves of the body and the cores in one operation on the press
Documenting the Foundry Process 2 haves of the tooling create the body shell in resin sand 2 haves of the tooling create the valve core in resin sand
Documenting the Foundry Process Body shells and cores are assembled in 4 cavities Assembled shells are stacked for moving to the foundry
Documenting the Foundry Process The melt is prepared and slag removed Additives to inoculate the iron are weighed out and added to the intermediate ladle The Iron is transferred to the ladle The ductile iron is transferred to a tea pot ladle for pouring The temperature is recorded using a zirconium probe
Documenting the Foundry Process The tea pot ladle used by TOCA is common in steel casting and is an interesting innovation in this foundry Applying it in DI casting process will likely yield better quality castings with better control over porosity and impurities A simple 2 man system allows the pour from the tea pot ladle to be carefully controlled
Documenting the Foundry Process The sand resin shells are packed into a box and filled with fine gravel and tamped down to pack the box The cast parts are allowed to cool and solidify with uniform heat dissipation The DI is poured from the tea pot ladle filling each shell
Documenting the Foundry Process After the cast parts have cooled the box is tipped out and the parts separated from the gravel and remains of the shell Parts broken out from the resin sand shells
Documenting the Finishing Process After the parts have cooled they are brought to the grinding room Individual parts are separated, gates, risers and flash are removed and a visual inspection performed
Documenting the Finishing Process Good parts are cleaned and pack for shipment to the machine shop or customer Parts not passing inspection are quarantined for rework or scrap
Finished Parts The parts show consistent, good quality surface finish Lettering and marking are clear and legible with excellent detail
Quality Process Foundry work instructions are posted on the foundry wall Since this foundry only makes Ductile Iron this practice is acceptable. If multiple grades and other materials are introduced this method may need to be revised Detailed work instructions A white board is used to post detailed work instructions related to specific parts in production at a point in time It provides details on order quantity and other specifics related to the part
Quality Process Parts are inspected in the finishing process, specific defects are illustrated on work instruction at the inspection station Rework station
Quality Process A Spark Emission Spectrometer is used to qualitatively asses the melt chemistry after inoculation with the nodulating additives Lab technician performing a macro structure assessment on a sample Spectrometer calibration samples
Quality Process Coupons are poured with each heat Samples are kept for 1 year unless otherwise specified by the customer Chemical composition and micro structure are recorded Quality Management System ISO9001 Certification
Business Overview / Summary TOCA was established in 1989 in Canada by President and Owner Mr. John Fan. John was born and raised in China and devotes much of his time in overseeing the China activities required to meet some of the most demanding requirements. The company initially established a vendor source group comprising of manufactures of metal products of a wide variety using several different manufacturing processes. While many sources continue to be used the company now focuses on products manufactured in its own steel and ductile iron foundries, fabrication and machine facilities, which are supported by assembly, inspection, and warehouse distribution operations of the company. TOCA s, Cato International Co. Ltd., Operations, are headquartered in Tianjin, Steel foundry operations in Zhangjiakou, Ductile Iron foundry operations in Dingzhou, and Fabrication, Machining, Assembly, Warehousing, and administrative support operations in Tianjin. TOCA is a leading supplier of heavy duty trailer and chassis components to original equipment manufactures and aftermarket distributers. We also specializes in supplying carbon, low alloy, high alloy stainless steel castings and forgings, ductile iron castings, aluminum castings and die castings, stampings, fabrications, and also provides a variety of other metal products. Complete machining, assembly, painting, plating, and other additional operation can be provided. With an experienced staff located in the USA and in China TOCA has the ability to provide quality conforming prototypes, first article samples, and production parts produced in China. Fast turnaround on new projects is our goal and our strategic USA and China quality assurance and warehouse locations provide us the ability to stock agreed upon quantities of your products approved for production. USA Operations: Headquarters in Manteno, IL (Chicago area) are located near a rail container delivery center, consists of corporate offices and warehouse facilities in excess of 30,000 sq. ft. Administration, quality assurance and product distribution activities are performed at this location. In addition TOCA USA has several agreements involving products inventoried at customer facilities to assure all requirements are met. Sales and engineering staff are located in Muskegon, MI near the beautiful shores of Lake Michigan. The sales and engineering employees have been in involved in the casting, fabrication, and assembly manufacturing business in the USA and have years of experience. Total Customer Satisfaction is our goal and we look forward to the opportunity to become a supplier to your company. You can be assured we will work with you to improve quality, service, shorten cycle time, and reduce costs.
Business Overview / Summary TOCA Ductile Iron Casting, Dingzhou, Baoding, Hebei Province MOLDING & CORE EQUIPMENT IRON PATTERN PRE-COATED SAND PRODUCTION LINE HORIZONTAL PARTED SHELL MACHINE 425mm X 425mm HORIZONTAL PARTED SHELL MACHINE 630mm X 630mm VERTICAL PARTED SHELL MACHINE 500mm X 300mm SMALL CORE MACHINE VARIABLE SIZE MELTING FURNACES Electric induction melting furnaces size.35 metric tons CLEANING EQUIPMENT Cutting Equipment Variety of hand and stand grinding equipment Tumble blast machine HEAT TREATING EQUIPMENT Quench, Temper, Austemper performed by TOCA approved source INSPECTION EQUIPMENT QUALITY MANAGEMENT SYSTEM CERTIFIED TO CONFORM TO ISO 9001:2000 Spectrograph chemical analysis machine Metallographic analysis equipment Tensile testing machine Digital portable pyrometer Certified X-ray inspection contracted with local laboratory
Business Overview / Summary