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Challenges

The Demanding Requirements of CNC Machinery for Foundational Components

The performance of CNC Machinery depends on micron-level motion control and structural integrity. Structural components such as machine beds, columns, and frames are not just support elements – they are the foundation of precision machining. Any compromise in rigidity, stability, or thermal performance directly impacts machining accuracy, surface finish, and equipment longevity.

Vibration Damping & Thermal Stability

During high-speed and high-dynamic machining, even minor vibrations or thermal expansion in structural components can lead to toolpath deviations and loss of workpiece accuracy. Foundational castings must provide superior vibration absorption and long-term thermal stability to ensure consistent positioning and repeatable precision under varying operating conditions.

Material Homogeneity & Structural Integrity

CNC machinery endures continuous cyclic loads and high dynamic stresses over its lifetime. Structural castings must exhibit high density, uniform microstructure, and excellent fatigue resistance. Internal defects such as porosity, shrinkage, or residual stress can lead to deformation or cracking under sustained loads, compromising machine stiffness and service life.

Structural Rigidity

The cutting forces, inertial loads, and rapid acceleration/deceleration during machining demand exceptionally high static and dynamic rigidity in foundational components. This ensures positional stability between the tool and workpiece, while maintaining geometric accuracy and reliability throughout millions of operational cycles.

Process

KBR CNC Solution Matrix

CNC Machinery Challenges	Required Material Properties	KBR's Verifiable Solutions & Evidence
Suppressing Machining Vibration for Superior Surface Finish	Excellent Vibration Damping & High Rigidity	High-Grade Gray Iron (HT300-HT350): Provides superior vibration damping and structural stiffness, effectively absorbing machining vibrations. Ideal for high-precision machine tool beds and bases.
Ensuring Long-Term Geometric Accuracy	Low Thermal Expansion & High Dimensional Stability	Mechanite® Cast Iron & Ductile Iron (QT450-10): Advanced casting processes ensure uniform material structure and minimal thermal distortion, maintaining positioning accuracy under temperature variations.
Withstanding Heavy & Dynamic Loads	High Strength & Superior Fatigue Resistance	High-Strength Ductile Iron & Alloyed Cast Iron: Suitable for structural components in high-speed machining centers and heavy-duty gantry machines. Tensile strength exceeds 450MPa, validated by FEA and fatigue testing.
Achieving Micron-Level Motion Precision	High Dimensional Accuracy & Machining Consistency	In-House Precision Machining & 3D Scanning Inspection: Utilizes 5-face machining centers and large gantry mills to achieve key mating surface accuracy within ±0.02mm, validated with full-field scanning for geometric tolerance verification.
Ensuring Long-Term Reliability & Cost-Effective Maintenance	Traceable & Verifiable Quality System	ISO 9001:2015 Certified System & In-House Material Lab: Provides full-process testing including mechanical properties, metallographic analysis, and ultrasonic inspection, ensuring consistent material performance batch after batch.

Quality Control

Qualification Through Verification:
Our Commitment to Quality

In high-stakes manufacturing, trust is earned through proof. Our quality system is not just a certificate on the wall; it is an integrated, data-driven process designed to mitigate risk and ensure absolute conformance to your specifications.Our entire operation is certified to the ISO 9001:2015 standard, ensuring a systematic, repeatable, and documented approach to quality assurance.

Quality Control

Comprehensive In-House
Metrology & Testing

We validate every critical parameter in our dedicated quality lab, providing you with complete transparency and verifiable data.

Spectrometer

To verify the precise chemical composition of every melt, ensuring material properties meet specifications like HT300 or QT450-15.

Tensile Strength & Hardness Testers

To confirm that the final casting possesses the required mechanical properties for strength, durability, and wear resistance.

Ultrasonic Flaw Detector

To perform ultrasonic inspection for castings. This ultrasonic flaw detection inspects the internal structure for subsurface porosity or inclusions, a critical step to prevent outgassing in vacuum components.

Metallographic Microscope

To examine the material's microstructure (e.g., graphite flake size in gray iron or nodularity in ductile iron), which dictates its performance characteristics.

3D Scanner

To perform 3D scanning for castings. This CAD-to-part inspection provides high-precision dimensional verification against the original CAD model, ensuring accuracy and conformance.

Projects

Typical Components forHigh-Performance Equipment

Car-milling composite base casting component.jpg

Turn-milling Composite Machine Castings :
One-piece Casting Reduces Assembly Errors & Boosts Machining Stability

Process:Resin Sand Casting

Material:HT300 Gray Iron

Weight:3,519 kg

One-process complete forming | Reduces clamping errors and increases processing efficiency by 30%+

Machine tool base:
High-end CNC machine tool base casting

Process:Resin Sand Casting

Material:HT350 Gray Iron

Weight:1219 kg

The multiple aging treatment process is adopted to completely release the casting stress.

Capabilities

Mastering the Craft : Our Dual Casting Processes

Request Casting Process Solution

Resin Sand Process

Coated Sand Process

Resin Sand Process

For Large-Scale & Heavy-Duty Castings

Our Resin Sand process is ideal for producing large, heavy, and structurally demanding castings. Using robust metal or wood patterns, High-strength sand shell, with a smaller draft angle,24 to 72 hours of insulation time.this process provides a cost-effective solution for low-to-medium volume production runs where structural integrity is paramount.

Key Specifications Table

Casting Weight: 50 kg – 10,000 kg

Best For: Low-to-medium volume (tens to hundreds annually)

Materials: Gray Iron (HT200,HT250,HT300,).Ductile Iron (QT400-QT450-QT500-QT600)

Applications: Machine Tool Bases, Large Housings, Construction Machinery Frames

Coated Sand Process

For High-Precision & High-Volume Components

When precision and surface finish are critical, our Coated Sand process delivers exceptional results. Using high-precision, long-life iron molds (100,000+ uses), By using the core shooter, we can produce more precise sand molds with a smaller draft angle.we achieve accuracy errors within 0.5mm, the surface roughness reaches Ra25.making it perfect for complex parts in high-volume production.

Key Specifications Table

Casting Weight: 5 kg – 1,000 kg

Best For: Hundreds to tens of thousands

Materials: Gray Iron (HT200,HT250,HT300,).Ductile Iron (QT400-QT450-QT500-QT600)

Applications: Valve, Cylinder block, Transmission parts

Trusted by Leading OEMs Worldwide for Gray & Ductile Iron Castings

Talk to us

Let's Build Your Next Great Component

Whether you have a complete CAD model or are in the early stages of design, we can provide expert guidance on material selection, process optimization, and design for manufacturability to ensure your project's success.

Discover Keboer

High-Stability CNC Machine Casting

Challenges

The Demanding Requirements of CNC Machinery for Foundational Components

Vibration Damping & Thermal Stability

Material Homogeneity & Structural Integrity

Structural Rigidity

Process

KBR CNC Solution Matrix

Quality Control

Qualification Through Verification: Our Commitment to Quality

Quality Control

Comprehensive In-House Metrology & Testing

Spectrometer

Tensile Strength & Hardness Testers

Ultrasonic Flaw Detector

Metallographic Microscope

3D Scanner

Projects

Typical Components forHigh-Performance Equipment

Turn-milling Composite Machine Castings :One-piece Casting Reduces Assembly Errors & Boosts Machining Stability

One-process complete forming | Reduces clamping errors and increases processing efficiency by 30%+

Machine tool base:High-end CNC machine tool base casting

The multiple aging treatment process is adopted to completely release the casting stress.

Capabilities

Mastering the Craft : Our Dual Casting Processes

Resin Sand Process

For Large-Scale & Heavy-Duty Castings

Key Specifications Table

Coated Sand Process

For High-Precision & High-Volume Components

Key Specifications Table

Trusted by Leading OEMs Worldwide for Gray & Ductile Iron Castings

Talk to us

Let's Build Your Next Great Component

Email

Phone / WhatsApp

Shanghai Office

Anhui Factory

Capabilities

VMC Casting Solutions

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Qualification Through Verification:
Our Commitment to Quality

Comprehensive In-House
Metrology & Testing

Turn-milling Composite Machine Castings :
One-piece Casting Reduces Assembly Errors & Boosts Machining Stability

Machine tool base:
High-end CNC machine tool base casting