Investment casting offered by us is the process that uses a wax as well as thermoplastic pattern and is equipped with refractory slurry for forming a mold. It is a processing method where melted metal is casted into a form by surrounding a replaceable model with slurry that sets at room temperature. It is used for small castings and also to produce entire aircraft door frames along with steel castings of up to 300 kg and aluminum castings of up to 30 kg.
 
 Features of Investment Casting:

• Allows Undercuts in the pattern
• Tolerance of 0.5 % of length are possible, and for small dimensions it can be as low as 0.15 %
• Weight of the castings can range from a few  grams for 60 Kgs
• Minimum wall thicknesses are about 0.5 mm to 1.0 mm
• Parts do not require machining because of the closed tolerances
• Smooth surface finish
• Excellent  production rates, particularly for small components
• Through dimensional accuracy and consistency
• High integrity castings
• Machining can be eliminates
• Minimal shot blast and grinding needed

Application of Investment Casting:
 
Typically materials that can be cast with this process are Aluminium alloys, Bronzes, Stainless Steels, Stellite etc. Glass mold accessory castings, valves and fittings, gears, Levers and Splines are some of the popular usages.

Material of construction:

All kind of ferreou

This process can be categorized as similar to that of  permanent mold method, Here as the molten metal is being poured,  a permanent metal mold revolved about its axis at high speeds ranging from 300 to 3000 rpm. This can be in horizontal, vertical or inclined positions. As a result, the molten metal is centrifugally thrown towards the inside mold wall. There is solidifies after cooling. It’s usually a fine grain casting with a very fine-grained pouter diameter.
 
Molds for Centrifugal castings can be divided into three types :

• The Permanent Mold:  Made of steel, iron or graphite. Inside surface is coated with a thin refractory wash to increase mold life. The mold is preheated before coating, so as to dry the coating and improve the adherence to the mold surface.
•  Rammed Mold: It consists of a steel metal flask, lined with a layer of refractory molding mix. The inside lining is coated with a refractory wash which is baked until dry and hard.
•  Spun or Centrifugally Cast Mold: In the metal flask a predetermined mass of refractory materials in slurry form is poured.

 
The flask on rotation makes the refractory materials centrifuged onto the wall of the flask. The rotation is stopped and the liquid portion of the slurry drained off. It leaves the mold with a refractory coating, to be baked until dry before use.
 
Features of Centrifugal Casting :

•  Castings can be made is almost any length, thickness and diameter.
•  Different wall thicknesses can be produced from the same size mold
•  Eliminated the need for cores.
•  Resistant to atmospheric corrosion, a typical situation with pipes.
•  Mechanical properties of centrifugal castings are excellent
•  Only cylindrical shapes can be produced with this process.
•  Size limited are up to 3m (10 feet)  diameter and 15m(50  feet) length
•  Wall thickness range from 2.5mm to 125 mm (0.1-5.0in)
•  Tolerance Limit : On the OD can be 2.5 mm (0.1 in ) on the IS can be 3.8mm(0.15in)
•  Surface finish ranges from 2.5 mm to 12.5 mm(0.1 -0.5in)rms

 
Application :

Typical materials that can be cast with this process are iron, steel, stainless steels and alloys of aluminium, copper and nickel. Two materials can be cast by introducing a second material during the process. Typical parts made by this process are pipes, boilers, pressure vessels, fly wheels, cylinder liners and other parts that are ax-symmetric.
 
Type of Centrifugal Casting:

•  Semi-Centrifugal Casting
•  Centrifugin

Sand casting offered by us is well known process that facilitates the less significant batches that is to be made and are compared to enduring mold casting.  We offer this process at the market leading prices and also make the fabrication of many products very easy. It benefits sand casting, such as very small size operations and allows many metals to bed casted. Following are the salient features of the process:
 

• Mass limit of 2300-2700 kg
• Minimum part weight ranges from 0.075-0.1 kg
• Can create the entire bed for one rail car

It is the most popular and most basic of all the casting processes along with being economical. first a cavity in the sane is formed by using a pattern made of wood or metal. The cavity is contained in a flask. Cores are put in the cavity to form holes of the desired shapes.

An extra void called Riser is created in the mold to contain excessive molten material. The purpose of this is to prevent voids in the main casting. Generally sand casing consists of a two-part Sand Casting Mold. While the upper part is called the Cope, the lower part is called the Drag. A parting line or surface separates the two.
 
Some portion of the drag is filled with sand. The cores, core print, and the gating system are placed near the parting line. The cope and the drag are assembled then sand is poured in the cope half. That covers the pattern, core and the gating system.

The sand gets compacted by vibration and other mechanical processes. After this, the cope is removed from the drag. The pattern is removed. Care is taken so that pattern is removed without breaking the mold cavity. This can be taken care of by designing a draft, which is usually a minimum of 1” or 1.5 mm (0.060 in), more rough the surface of the pattern, the more the draft to be provided.

We are excellent manufacturer and suplier of sand casting and sand mould casting products. The main disadvantage of sand mould casting process is that each time a casting is made, the mould is destroyed. The product is made as per clients' requirements and drawin.

Advantages

•      Least Expensive in small quantities (less than 100)
•      Ferrous and non - ferrous metals may be cast
•      Possible to cast very large parts
•      Least expensive tooling

 
Recommended Application
 

•    Use when strength/weight ratio permits
•    Tolerances, surface finish and low machining cost does not warrant a more expensive process
  

The metal pattern is first heated at a temperature of 200 ⁰ C / 392 ⁰ F.Then covered with a mixture of sand and thermo set plastic. It forms a skin of sand/ plastic mixture of about 3.5 mm (0.125 inch) which adheres to the pattern. The shell mold is formed after the skin gets removed from the pattern. The two halved of the shell mold are secured together and the metals id poured in the shell to form the part. Once the metals solidified, the shell is broken.
 
Features of Shell mold Casting:
 

•  Good Surface Finish : 1.25µm to3.75µm (50µin to 150µin)rms dimensional Tolerance of 0.5 %
•  Size Limits : 30 g to 12 kg (1 oz to 25lb)
•  Minimum Thicknesses :  As low as  1.5mm (0.062 in) to 6.25mm (0.25 in)depending on the material
•  Superior Machining Qualities :  As it has soft skins and hard or dense interiors
•  Draft Allowance :  Typically 1⁰ C

 
Application:
 
The materials that can be used with this process are aluminum, cast irons, and copper alloys. Parts made can be connecting rods, Gear Housings, Lever arms etc.

Castings in Copper Base Alloys, cast iron, aluminum alloys and others like zinc can be produced using this method. Though most of the end product is of aluminium castings typically the weight can range from ½ kg to 50kg.
 
The production of castings starts with selecting either a reusable mold or a die having two or more parts. The die would be complete with the impression of the casting along with running, feeding and venting systems. There is provision also for removal of the casting. To maintain the casting’s accuracy, the die can easily be cleared of debris such as hot metal splashes and sand. The die is quite capable of a regular cycle of production along with fast dissipation of heat of the metal poured into it.
 
Both simple ad complex quality castings can be produced. A unique feature of the gravity die casting methods is that it can handle heat treatment of high strength aluminium alloys that pressure die casting still cannot. Suitable for castings requiring complex intricate coring and small production runs.

Pressure die casting is a quick, reliable and cost –effective manufacturing process for production of high volume, metal components that are net-shaped have tight tolerances. Basically, the pressure die casting process consists of injecting under high pressure a molten metal alloy into a steel mold(or tool).This gets solidified rapidly(from milliseconds  to a few seconds) to form a net shaped components. It is then automatically extracted.
 
Advantages:
 

•  Lower Costs compared to other processes.
• Economical-typically production of any number of components from thousands to millions before requiring replacement is possible.
• Castings with close dimensional control and good surface finish.
• Castings with thin walls, and therefore are lighter in weight.
  

 
Applications:
 

•  Automotive parts like wheels, blocks, cylinder heads, manifolds etc.
• Aerospace castings
• Electric motor housings
• Kitchen ware such as pressure cooker
• Cabinets for the electronics industry
• General hardware appliances pump parts, plumbing parts
  

Hot forging has both technical and economical advantages. It provides high precision results along with reduced production times.

Typically a forged metal results in the following :

• Drawing Out of the Metal : Increased length decreased cross-section
• Upsetting the Metal : Decrease in length decreased cross-section

• Change in Length : Change in Cross-Section: resulting in favorable grain flow for strong parts

Tips for selecting the Right Forging Technology :

• Technology to remain competitive must come out with cost effective alternatives. That is the reason computer aided techniques like CAD, CAM,CAE and Finite Element analysis (FEA) based computer simulation, are used to selecting the right forging process
• Understanding the forged materials’ flow behaviour under processing conditions
• Knowledge of the die geometry and materials
• Environmental considerations
• Evaluating the mechanics of deformation process-stress and strain
• Friction and Lubricating processes
• Natured of the Forging Equipment

Applications of Forging Process : Wide Variety of uses in different kinds of industries.

Automobile Industry : wheel Spindles, Kingpins, Axle beams and shafts, torsion bars, balls studs, idler arms and steering arm.

Agro-Industries : Engine and Transmission components, levers, gears, shafts and spindles to tie-rod ends, spike harrow teeth and cultivator shafts.

Aerospace : Bulkheads, hinges, wing roots, engine mounts, brackets, beams, shafts, landing gear cylinders and struts, wheels, brake carriers and discs and arresting hooks, blades, buckets coupling etc.

Hand Tools: Sledges, Pliers, Hammers, Wrenches and Garden tools, as well as wire-rope clips, sockets, hooks, turnbuckles and eye bolts are common examples. Industrial Equipment:  Connecting rods, blanks, blocks, cylinders, discs, elbows, rings, T’s Shafts and Sleeves.

Methods of Forging :

• Impression Die Forgings
• Net Shape
• Open Die Forgings
• Press Forgings
• Roll Forgings
  
• Upset Forgings

Extrusion Process is used for manufacturing long and straight metal parts. The shape of the Cross-sections can be solid round, rectangular, to T shapes, L shapes and Tubes etc. Extrusion is done by squeezing the metal in a die by using a mechanical or hydraulic press.
 
Extrusions are capable of producing compressive and shear forces in the stock material. As tensile is not produced, this makes very high deformity a possibility without actually tearing the metal. A wear resistant material lines the cavity in which the raw, material is constrained. This helps to resist the high radial loads as the material is pushed into the die.
 
Features of Extrusion Process:

• Cost Effective: Minimizes the need for secondary machining process.
• Surface Finish :  For Steel is 3 µm;(125 µ in ) , for Aluminum and Magnesium-0.8 µm(30 µ in)
• Cross-Section  :Wide Variety of Cross-sections can be made
• Minimum Thickness : For  Steel 3 mm (0.120 in), for Aluminium and Magnesium 1 mm (0.040 in)
• Minimum Cross Section: For Steel 250 mm (0.4 in ) for steel
• Corner and Fillet Radii : 0.4 mm (0.015 in ) for Aluminium and Magnesium, for steel the minimum corner radius is 0.8 mm (0.030 in) and 4mm (0.120 in) Fillet radius.

Application of Extrusion Process:
 
Trim Parts as used in automobile and construction equipment, Railings, window frame members, structural parts etc.
 
Extrusion can be of two types:

Hot Extrusion:
Generally done at fairly high temperature, approximately at 50 to 75 % of the melting point of the metal. The Pressures range from 35-700 MP a (5076-101,525 psi). To Cool down the high temperatures and pressures and its adverse effect on the die life as well as other components, good lubrication is a must. Oil graphite and glass powder is preferred as lubricants.
 
Application of Hot Extrusion:
 
Aluminium, copper with their alloys is successfully used to manufacture products using hot extrusion process. Electrical wires, bars and tubes are some of the items produced.
 
Cold Extrusion:
 
Cold Extrusion takes place at room temperature or slightly elevates temperatures. This process is useful for withstanding the stresses created by extrusion.
 
The advantages of Cold Extrusion are :

• No Oxidation process
• Good Mechanical properties provided the temperatures created are below the re-crystallization temperature
• Good Surface Finish

Application of Cold Extrusion:

Examples of the metals that can be extruded are copper, lead, tin, aluminum alloys, titanium, molybdenum, vanadium, steel. Which are used to make parts like collapsible tubes, gear blanks, aluminum

We have been widely appreciated for our superior quality machine turned components. These component are designed to increase the efficiency of the machine and provide maintenance free service.

Our machine turned components are used for various applications in industries like material handling, textile industry, aerospace and have special significance in automotive industries. Our range of machine turned components include CNC turned components, precision turned components, CNC machined components and precision machined components. We are also capable of preparing prototypes and getting the products customized as per the requirements of various industries across the globe.

The products include :

Supplier of CNC Machined Precision Components for Automobiles, Valves, Pipelines and Drill Jig Bushings. The company specializes in manufacturing and supplying all types of Precision Machined Components used by several industries.

Our highly qualified engineers and other professionals develop international quality products to offer complete satisfaction to its valued customers
CNC turning parts and precision turning parts have become absolutely indispensable in matters of consistency and quality.

We offer CNC machined components with the increased automation of manufacturing processes. We have been catering to this need of different industries. In the last 10 years, it has evolved as a leading manufacturer and exporter of a comprehensive range of CNC machined components such as CNC turning parts and precision turning parts on Traub automates.

A deep understanding of the industry and requirements of the customers coupled with a sound technological expertise and experience on the part of its engineers has enabled the company to produce CNC machined components of the highest quality.

The company is engaged in the manufacture, trade, supply and export of the following: CNC turning parts; precision turning parts on Traub automates; job range OD 2 mm to 200 mm.

We are engaged in design and manufacture of special purpose machine tools required for high production rates with consistent quality which is today's need in engineering manufacture.

The machines are designed & developed for almost all metal cutting operations like turning, milling, boring, drilling, tapping, grinding etc. These are the machines which keep you way ahead of others if you are in high production industry like automobile component manufacture, electrical comp. mfg., valve or pump mfg. Industry etc.

We also are in the field of SPMs required in ammunition component manufacture where very high production rates are required. Apart from which we have experience in building machines handling explosive materials, testing equipments where very high precision is required etc.

We are a group of technocrats having good technical education as well as field experience in design & development. Excellent was started in 1990 with a development of auto trimming machine with production rate of 1000 Nos./hr. and immediately there after developed multispindle drives with eccentric spindles in 1991.

Initially it was a partnership firm with a small set-up but developed lot of import substitute products for ordnance factories and engineering industry at large.  The partnership firm was later on converted to a Private Limited Company in the year 2000.

Now we are fully geared with various departments like design, component manufacture, QC, assembly shop, Electrical department, marketing etc. with a team of about 80 persons working in various areas.

Leveraging upon abundant experience in this industry, we offer superior quality sheet metal fabrications, that are encountering wide demand in the markets. These fabrications are offered in corrosion proof metals, which impart them maximum durability. Easy to handle, these fabrications find application in diverse industries. Complying the international quality standards, our sheet metal fabrications are most competitively priced.