TOOLING PREPARATION

Dies are designed by using latest UNIGRAPHICS design software. Finish impression & blocker impression on dies are sinking on Vertical machining center (VMC). Addition facilities like EDM, Planner, milling machine, lathe, radial drill, pneumatic grinder for finishing available for trimming tools, coining die & other activity related tooling’s manufacturing. The raw material for dies is DIN-2714 harden & tempered.

TOOLING INSPECTION

Finish impression from dies are 100% dimensionally checked by LAYOUT ON POP (Plaster of paris) & data recorded before production. Trimming tools(die & punch)are used for trimming the excess material, is made by POP moulds. Trimming die edge is welded by hard facing welding rod & finishing by pneumatic grinder.

IN HOUSE METAL TESTING LABORATORY

Receipt of rounds and billets steel is identified by specified color codes to avoid mix-ups & stored in racks. As per steel supplier test certificate, steel material inspection & testing verified at in house Lab. Steel material is tested for chemical analysis, size, micro-cleanliness, macro-etch for inclusions, surface hardness for cold shearability & Physical testing if required (Outside NABL approved Lab.) Spark and spectral test are also carried out in-house as per customer requirement. After heat treatment, Microstructure & hardness, grain size, grain flow is checked as per quality plan at in house metallurgical Lab.

We always insist to purchase AL killed steel material from National reputed manufacturer & it must be processed in arc furnace, LRF & vacuum de-gases (VD) & as rolled with Minimum 6 (six) times reduction ratio for cast billet.

CUTTING

As per section size, blanks cutting are carried out on either 3” or 4” billet cold shearing machine or bend saw machine. Cut blanks weight is controlled by continuous monitoring on electronic digital weighing machine & recorded in given cutting slip before heating.

BLANKS HEATING

Heating of cut blanks is carried out in Natural Gas fired box & pusher type furnace as per section shape at 1150 C to 1250 C with proper shocking time. The temperature is monitored and controlled using thermocouple attached with furnace in order to avoid overheating & burning.

DROP FORGING

Forging process is carried out on drop hammer. Upsetting, Rolling, Pulling, bending operation is carried out to get nearer shape of finish impression on same dies. Excess material is trimmed on adjoined power press with die & punch. We can forge weighing from 100 grams to 15 kg. circular & profile single component in carbon & alloy steel.

INHOUSE HEAT TREAMTMENT

As per customer requirement, forging undergo the normalizing, stress relieving, annealing as per qualified cycle. Heat treatment cycles (Temp. V/s Time) are recorded & controlled by PLC base microprocessor. Continuous type heat treatment furnace with Quenched & tempered, ISO annealing facilities are in expansion project.

POST OPERATION - SHOT BLASTING

Forging surface de-scaling operation is carried out on In house shot blasting machine. We are using proper grade of steel shots to avoid pit marks & remove embossed marking. Then 100% fettling operation is conducted in house fettling shop to remove flash projection, burrs, chopping etc. After fettling 100% visual inspection is done & as per quality plan Pre Dispatch Inspection (PDI) report is carried out & sends along with forgings to customer.

QUALITY INSPECTION OF FINISH FORGING