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Die Casting Units Pune (Chakan) Greater Noida Product Range

Published byGuillermo Slagter Modified over 9 years ago

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Presentation on theme: "Die Casting Units Pune (Chakan) Greater Noida Product Range"— Presentation transcript:

1

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

3 Major Customers – Die Casting

4 Honda Amaze,City,Mobilio Diesel
Product Gallery-GDC Compressor 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

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

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

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 Machining Facility with cellular concept
GDC – Facility Die Casting Facility Machining Facility with cellular concept 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 GDC – Foundry Equipments
Core Making Machine Melting Furnace GDC Machine Sand Decoring Machine Capacity: Solid & hollow sand cores upto 5 mm thickness Total machine: 03nos Machine Feature: Shell cores can be made solid as well as hollow up to 5.0 mm thick Both side shooting facility & Rollover with control parameter Capacity: 250, 500 & 750kg molten metal / hr Total machine: 3 nos Machine Feature: Gas Fired fully automatic Castable inside lining Capacity: Max 950X950mm pattern size Total Machine: 10nos Machine Feature: Can be operated from 0-90° Temperature locking system Capacity : 500X500X250mm Size can be tested Machine Feature: Fully Automatic. Various types of castings sand can be removed only by changing fixture. 2~5mg Millipore value can be achieve

11 GDC – Post Foundry Equipments
Raiser Cutting - SPM Heat Treatment – T6 Shot Blasting Machine Capacity : 500X300X300mm Total machine: 3nos Machine Feature: Two casting can cut at time Changeable fixtures Capacity: 1000Kg & 500Kg Solutionizing + Ageing furnace Total machine : 2nos Machine Feature: PLC controlled Capacity: Max500kg Machine Feature: PLC Controlled Various types of castings be Shot blasted. Surface roughness 4~6 Ra can be achieve

12 Machining & Post Machining Equipments
CNC Turning Machine VMC Washing Machine Capacity: 350mm Turn Diameter Total machine: 4 nos Machine Feature: Various types of castings can be machining by changing chuck Run out accuracy 5-10µm can be achieved Capacity: Bed size 1000X450 mm Total machine: 10 nos Machine Feature: Various types of castings can be machining by changing Fixture 12nos tool holder pocket Capacity: Four casting in one cycle Machine Feature: Can achieve 2~ 8 mg Millipore value Parts is rotation 360° while washing Various types of casting can washed by changing fixture.

13 Machining & Post Machining Equipments
Leak Testing Machine Electronic Gauging Child Part Assembly Capacity : 800X500X300mm Size can be tested Machine Feature: Wet & dry leak testing can be done. Various types of castings can be leak tested only by changing fixture. Parts can be tested at 1-4bar Capacity: 600pcs /Day Total machine: 2nos Machine Feature: Critical / significant dimn 100% check Automatic data storage Automatic SPC processing Capacity: 1000pcs /day Total machine: 2nos Machine Feature: Pokoyoke done in machine Assembly dimn can maintain with in ±0.1mm

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

15 Product Gallery- Aluminium PDC
Master Cylinders Converted from GDC to PDC Head Cover Starter 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 Buhler 530T machine with Fondrex Vacuum Unit
Aluminium PDC Machines Buhler 530T machine with Fondrex Vacuum Unit 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.

19 Product Gallery- ZINC PDC
Fuel Tank Body (Scooty) Fuel Tank Lid (Scooty) Starter Lock Body (Scooty) Lock Body Cam Fuel Tank Lid (Pulsar 150,180) Fuel Tank Body (Pulsar 150,180) Lock Body (Discover, Pulsar)

20 Product Gallery- ZINC PDC
Lock Body (Scorpio, Xylo) Lock Body (Sumo, Safari) Lock Parts (Figo) Cam Lock Parts (Micra) Lock Body (Alto) Lock Parts (Beat)

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

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

23 Zinc Pressure Die Casting (Hot chamber)
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.

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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