An innovative automotive foundry for the 21st century

The automobile industry currently faces many challenges that may greatly impact its foundry operations. One of these challenges-consumers' demand for greater-fuel efficiency-can be met by I-educing the weight of castings used in automobiles, and minimizing engineering tolerances. In answer to this particular demand, engine foundries have begun to produce cylinder blocks or other castings with aluminum rather than cast iron, or so focus on producing near-net-shape iron castings. Near-net-shape iron castings also have the added benefit of reducing casting cost. Automotive foundries must also be concerned with environmental issues, such as energy conservation, waste reduction, strict environmental regulations and clean working environments. In addition, all automotive foundries are competing with each other to achieve higher levels of quality control, productivity and facility modernization. This paper will discuss how Toyota is meeting these challenges with one of our newest foundry production lines. Ar the core of this new production line are sever al keg. systems. One key system is a highly automated molding line equipped with an airflow and squeeze (Seiatsu) molding process, which assures production of molds with superior dimensional accuracy and mold strength. Other key systems include a coldbox core system, and a molding sand preparation plans featuring a vacuum mixing process. Although the initial cost was prohibitive, a type of synthetic ceramic sand was adopted as the base sand for the entire plant, in expectation of long-term benefits. Through the extensive development and utilization of these sophisticated production tools and their related technologies, an engineering standard for producing thin-wall cylinder blocks has been established. At the same time, the plant has achieved its target of suppressing environmental hazards and reducing energy consumption. We believe that this foundry represents a cost-effective guideline for 21st century automotive industry foundries, in terms of increasing production capacity, efficient use and maintenance of equipment and a cleaner, safer working environment.