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