die casting units pune (chakan)greater noida product rangealuminium : hpdc, gdc with machining,...

Die Casting Units

Pune (Chakan) Greater Noida

Product Range Aluminium : HPDC, GDC with machining, powder coating & sub assembliesZinc : Hot chamber with machining & surface finishingLPDC : Planned

No. of Employees Pune : 474 , G Noida : 310 ; Total = 784 Nos.

Quality Certification ISO 9001:2008, ISO 14001, ISO/TS 16949:2009

Major Customers – Die Casting

Product Gallery-GDCCompressor Housings : (Honeywell )

Honda Amaze,City,Mobilio Diesel

Hyundai i10 Grand Diesel

Volvo MD8 Trucks Volvo MD5 Buses

Intake Manifolds

3 Port 4 Port Intake Pipe

Product Gallery-GDCCaliper Body Disc brake application

(Pulsar 135, 150, 200NS)

Upper Brackets

Handlebar Holders

Product Gallery-GDCTandem Master Cylinder Brake application (Three wh. & 2 Ton commercial veh.)

Upper Riser Lower Riser

Handle Brackets

Upper Bracket

Typical GDC Process Flow Diagram

Receipt Of Ingot

Melting

Gravity Die Casting

T6 Heat Treatment

CNC + VMCMachining

Packing

FinishGoods

Infrastructure

Gravity Die Casting

Die Casting Facility Machining Facility with cellular concept

GDC – Facility

Machines Capacity : Casting weight upto 15 KgTechnology : 0˚ to 90˚ Tilting with PLC Controlled Other Facility : Sand Core Shooters, T6 Heat Treatment Furnaces ,Sand de-coring ,Gate cutting SPMs etc.

Machines Capacity : CNC Turn dia. 350 mm & VMC bed size 1000X450 mm Technology : Rotary indexing Hydraulic fixtures ,tool breakage sensors, SPMsOther Facility : Washing, Leak test , Child part assembly, electronic gauging etc.

Capacity : 500X500X250mm Size can be tested Machine Feature: 1. Fully Automatic.2. Various types of

castings sand can be removed only by changing fixture.

3. 2~5mg Millipore value can be achieve

Capacity: Max 950X950mm pattern size Total Machine: 10nos Machine Feature: 1. Can be operated from

0-90°2. Temperature locking

system

Capacity: 250, 500 & 750kg molten metal / hr Total machine: 3 nos Machine Feature: 1. Gas Fired fully

automatic 2. Castable inside lining

Capacity: Solid & hollow sand cores upto 5 mm thickness Total machine: 03nos Machine Feature: 1. Shell cores can be

made solid as well as hollow up to 5.0 mm thick

2. Both side shooting facility & Rollover with control parameter

GDC – Foundry Equipments

Sand Decoring MachineGDC MachineMelting FurnaceCore Making Machine

Capacity: Max500kg Machine Feature:

1. PLC Controlled 2. Various types of

castings be Shot blasted.3. Surface roughness 4~6

Ra can be achieve

Capacity: 1000Kg & 500Kg Solutionizing + Ageing furnace Total machine : 2nos Machine Feature:

1. PLC controlled

Capacity : 500X300X300mm Total machine: 3nos Machine Feature:

1. Two casting can cut at time

2. Changeable fixtures

GDC – Post Foundry Equipments

Shot Blasting MachineHeat Treatment – T6Raiser Cutting - SPM

Capacity: Bed size 1000X450 mm Total machine: 10 nos Machine Feature: 1. Various types of castings

can be machining by changing Fixture

2. 12nos tool holder pocket

Capacity: 350mm Turn Diameter Total machine: 4 nos Machine Feature: 1. Various types of castings

can be machining by changing chuck

2. Run out accuracy 5-10µm can be achieved

Machining & Post Machining Equipments

VMCCNC Turning Machine

Capacity: Four casting in one cycle Machine Feature: 1. Can achieve 2~ 8 mg

Millipore value 2. Parts is rotation 360°

while washing3. Various types of casting

can washed by changing fixture.

Washing Machine

Capacity: 1000pcs /day Total machine: 2nos Machine Feature: 1. Pokoyoke done in

machine2. Assembly dimn can

maintain with in ±0.1mm

Capacity: 600pcs /Day Total machine: 2nos Machine Feature: 1. Critical / significant dimn

100% check2. Automatic data storage3. Automatic SPC

processing

Machining & Post Machining Equipments

Child Part AssemblyElectronic Gauging

Capacity : 800X500X300mm Size can be tested Machine Feature: 1. Wet & dry leak testing

can be done.2. Various types of castings

can be leak tested only by changing fixture.

3. Parts can be tested at 1-4bar

Leak Testing Machine

Product Gallery- Aluminium PDCStep Holders

Top

Handlebar Holders

Engine Stay Rider Pillion

Bottom

Engine Stay Rider Pillion

Product Gallery- Aluminium PDC Master Cylinders Converted from GDC to PDC

Head Cover Starter Cover Fuel Tank Lid

Aluminium PDC Process Flow Diagram

Receipt Of Alloy

Alloy Melting

PressureDie

Casting

Fettling &

Finishing

Machining

Packing FinishGoods

Painting

Infrastructure

Pressure Die Casting

State of Art PLC/CNC Controlled with partial & complete vacuum system Capacity : 135 to 530 Tons Locking Force Machine make : Buhler, Toshiba No. of Machines : Pune - 10 nos , G Noida - 2 Nos.

Aluminium PDC Machines

Buhler 530T machine with Fondrex Vacuum

Unit

Product Gallery- ZINC PDC

Cam

Fuel Tank Body(Scooty)

Lock Body

Fuel Tank Lid(Pulsar 150,180)

Fuel Tank Body(Pulsar 150,180)

Lock Body(Discover, Pulsar)

Starter Lock Body (Scooty)

Fuel Tank Lid(Scooty)

Product Gallery- ZINC PDC

Cam

Lock Body (Scorpio, Xylo)

Lock Body (Alto)Lock Parts (Micra)

Lock Body (Sumo, Safari) Lock Parts (Figo)

Lock Parts (Beat)

Product Gallery- ZINC PDC

Cam

Base Surround (Legrand)

Valve Body Housing Body Base

Actuator Block

Zinc PDC Process Flow Diagram

Receipt Of Alloy

Alloy Melting

DieCasting

Fettling &

Finishing

Machining

Packing

FinishGoods

Painting

Complete Automatic Zinc PDC machines Cellular Concept Layout – Die casting till packing in one single cell Capacity : 30 to 280 Tons locking force Make : Producer No. of machines : Pune - 22nos , G Noida – 24 nos.

Zinc Pressure Die Casting (Hot chamber)

Infrastructure

Quality Lab

Inspection Facilities• Density Index for Hydrogen gas analysis

• K mould for oxide / inclusion detection

• Spectrometer : Spectromax

• CMM : Accurate Spectra

• Profile Projector

• Microscope with Particle Size Analyzer

• Millipore Test Rig

• Boroscope

• Hardness Tester : Rockwell B & C Scale , Brinell

• Sand Testing Equipments : Sieve Shaker, Scratch Hardness etc.

Infrastructure

Tooling Manufacturing

Design & Engineering Facilities

Designing Capabilities :• AutoCAD• Solid Works • Unigraphics Mac 1• Casting Simulation for Zinc & Aluminium

Engineering Capabilities :• Tooling design & manufacturing• Machining Fixtures design & manufacturing• Leak testing , washing fixtures design & manufacturing• Sub-assembly fixture designing & manufacturing

Tool Manufacturing Facilities

Software used for Die Manufacturing :• AutoCAD • Delcam

Tool Room Equipments :• VMC – HASS, MAKINO F5 • CNC Wire EDM – FANUC, AGIE & Charmilles• Other Conventional Machines

Thank You !For further information please contact anil.chore@mindacorporation.com

Visit us at www.minda.co.in