Machining

İstikamet Döküm does not only leave ductile iron, grey iron, and steel alloy parts produced with advanced technology in its foundry as raw castings; it makes them ready for assembly in its high-tech machining plant designed according to IATF 16949 (Automotive Quality Management System) and ISO 9001 standards.

Our machining department has the capability to machine parts requiring high precision with micron-level tolerances, such as automotive axle and suspension components with complex geometries, tractor gearbox and differential housings, valve bodies, and offshore wind turbine anchorage apparatuses.

1. Precise Tolerances and Advanced Technology CNC Machinery Park

Our modern machining plant has a wide CNC machinery park capable of multi-axis simultaneous processing, consisting of Japanese technology Mazak and high-performance Avea/Ares vertical machining centers:

2. Featured CNC Machining Centers and Technical Capacities

Mazak Variaxis i-800T (Simultaneous 5-Axis Multi-Tasking Center)

It performs both turning and 5-axis milling operations (Multi-Tasking) of high-tech cast parts with complex geometries in a single setup:

• Machining Capacity: Maximum part diameter is Ø1000 mm x 375 mm or Ø800 mm x 500 mm.
• Axis Travels: It has stroke values of X: 730 mm, Y: 850 mm, Z: 560 mm.
• Table Tilting and Rotation Capability: It has a tilting capability between -130° and +30° on the A-axis (table tilting) and a 360° continuous rotation feature on the C-axis (table rotation).
• Spindle: It features a spindle speed of 10.000 rpm and MAS BT 50 / CAT 50 spindle taper.
• Rapid Traverse Rates: It offers a traverse performance of 42 m/min in the X, Y, and Z axes.

Mazak HCN 8800 (4-Axis Horizontal Machining Center)

It is designed for high-torque and precise machining operations of heavy-duty large cast parts:

• Machining Capacity: Maximum part diameter is 1.450 mm and maximum height is 1.450 mm.
• Axis Travels: It has axis strokes of X: 1.400 mm, Y: 1.200 mm, Z: 1.325 mm.
• Pallet Dimensions: It has an 800 mm x 800 mm dual-pallet automatic pallet changer (APC) system.
• Power and Spindle: It features a 37.0 kW main motor power, 7/24 taper No. 5 spindle nose structure, and a maximum speed of 10.000 rpm.
• Tool Capacity (ATC): It features an automatic tool changer containing 60 standard tool pockets.

Mazak Quick Turn 250MAL (C-Axis Turning Lathe with Live Tooling)

It integrates fast turning and auxiliary milling processes of precise circular cast parts:

• Capacity: It offers an 8-inch chuck size, 660 mm maximum swing diameter, and 360 mm maximum machining diameter.
• Main Spindle: It reaches a maximum speed of 5.000 rpm and 358 Nm torque with 18.5 kW motor power.
• Turret Configuration: It has a 12-station turret configuration, all of which are live tooling. The live tools operate at a speed of 5.000 rpm with 3.7 kW power.

3. Zero-Defect Target via Engineering and MagmaSoft Integration

The success of our machining processes begins before the part is even cast. Our design and R&D department analyzes micro-shrinkage, porosity, and stresses that may occur during casting, utilizing the MagmaSoft casting simulation.

The machining allowances and reference points of parts to undergo machining are determined in the CAD/CAM environment in line with MagmaSoft simulation data. Thanks to this integration, hidden casting defects during precise machining operations are prevented, achieving zero-defect manufacturing to automotive standards.