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Die Casting Units Pune (Chakan)Greater Noida Product RangeAluminium : HPDC, GDC with machining, powder coating & sub assemblies Zinc : Hot chamber with.

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Presentation on theme: "Die Casting Units Pune (Chakan)Greater Noida Product RangeAluminium : HPDC, GDC with machining, powder coating & sub assemblies Zinc : Hot chamber with."— Presentation transcript:

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2 Die Casting Units Pune (Chakan)Greater Noida Product RangeAluminium : HPDC, GDC with machining, powder coating & sub assemblies Zinc : Hot chamber with machining & surface finishing LPDC : Planned No. of EmployeesPune : 474, G Noida : 310 ; Total = 784 Nos. Quality CertificationISO 9001:2008, ISO 14001, ISO/TS 16949:2009

3 Major Customers – Die Casting

4 Product Gallery-GDC Compressor Housings : (Honeywell ) Honda Amaze,City,Mobilio Diesel Hyundai i10 Grand Diesel Volvo MD8 Trucks Volvo MD5 Buses Intake Manifolds 3 Port4 PortIntake Pipe

5 Product Gallery-GDC Caliper Body Disc brake application (Pulsar 135, 150, 200NS) Upper Brackets Handlebar Holders

6 Product Gallery-GDC Tandem Master Cylinder Brake application (Three wh. & 2 Ton commercial veh.) Upper RiserLower Riser Handle Brackets Upper Bracket

7 Typical GDC Process Flow Diagram Receipt Of Ingot Melting Gravity Die Casting T6 Heat Treatment CNC + VMC Machining Packing Finish Goods

8 Infrastructure Gravity Die Casting

9 Die Casting FacilityMachining Facility with cellular concept GDC – Facility Machines Capacity : Casting weight upto 15 Kg Technology : 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, SPMs Other Facility : Washing, Leak test, Child part assembly, electronic gauging etc.

10  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 Machine GDC Machine Melting Furnace Core Making Machine

11  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 Machine Heat Treatment – T6 Raiser Cutting - SPM

12  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 VMC CNC Turning Machine  Capacity: Four casting in one cycle  Machine Feature: 1.Can achieve 2~ 8 mg Millipore value 2.Parts is rotation 360° while washing 3.Various types of casting can washed by changing fixture. Washing Machine

13  Capacity: 1000pcs /day  Total machine: 2nos  Machine Feature: 1.Pokoyoke done in machine 2.Assembly dimn can maintain with in ±0.1mm  Capacity: 600pcs /Day  Total machine: 2nos  Machine Feature: 1.Critical / significant dimn 100% check 2.Automatic data storage 3.Automatic SPC processing Machining & Post Machining Equipments Child Part Assembly Electronic 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

14 Product Gallery- Aluminium PDC Step Holders Top Handlebar Holders Engine Stay Rider Pillion Bottom Engine Stay Rider Pillion

15 Product Gallery- Aluminium PDC Master Cylinders Converted from GDC to PDC Head CoverStarter Cover Fuel Tank Lid

16 Aluminium PDC Process Flow Diagram Receipt Of Alloy Alloy Melting Pressure Die Casting Fettling & Finishing Machining Packing Finish Goods Painting

17 Infrastructure Pressure Die Casting

18  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.  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

19 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)

20 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)

21 Product Gallery- ZINC PDC Cam Base Surround (Legrand) Valve BodyHousingBody Base Actuator Block

22 Zinc PDC Process Flow Diagram Receipt Of Alloy Alloy Melting Die Casting Fettling & Finishing Machining Packing Finish Goods Painting

23  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.  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)

24 Infrastructure Quality Lab

25 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.

26 Infrastructure Tooling Manufacturing

27 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

28 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

29 Thank You ! For further information please contact Visit us at


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