Our plant is located in the industrial township of CHAKAN in pune. The plant is spread over an area of 88,000 Sq.Ft. with covered area 15,000 Sq.Ft. The work floor layout is divided into three sections:
Forge Shop :Abrasive Bar Cutting Machine (20 M.M. Capacity)Several types of cutting machines are available for production cutting of tube and bar, such as cold saws, band saws, lasers, shears, waterjets, and abrasive cutting machines. While each has its advantages and disadvantages, abrasive cutting fills a niche with its ability to accommodate special applications, such as difficult-to-cut stock; tube that must be cut cleanly without serious distortion, especially very thin-walled tube; short cut lengths; and applications that require scrap minimization.
Abrasive Cuttings is the method of choice if :- A High Quality Cut Surface with minimal burr is required.
- Thin Walled Tube e.g. Stainless is to be cut without distortion.
- Small Diameter Bar and Tube Material cannot be cut by conventional sawing methods, e.g. Carbides, Hard Steels, Inconel, Ceramics.
- Sheets of Composites, Refractory Metals etc. need to be cut accurately to size
- Wire, Cable or Conduit needs to be cut cleanly with a smear free face to accept termination
Abrasive cutting does not compete with conventional saws such as band saws or circular/cold saws, but tackles the cutting of more difficult materials and fabrications, giving a high quality finish with minimum burr.
Metal Gathering Machine/Upsetting Machine (100 KVA S.P.M) :
Que. What is Electrical Upsetting ?
Ans. A high current is passed into one portion of the material to be upset. Due to the material resistance, heat is created. Once this portion of the material reaches a plastic state, cold material is pushed into the hot area via hydraulic force. During 'open' electrical upsetting, the bar material is positioned between the upsetting cylinder and the anvil plate or die. Two-part clamping jaws close around the bar and electrical current flows between the clamping jaws and anvil plate, heating the exposed portion of the component. The hydraulic cylinder exerts a controlled force on the cold end of the bar producing a shaped head. The material is upset to the required shape via the application of heat, pressure, flow, and linear travel. In 'open' upsetting techniques the component is then passed to a form tool [press] in the red hot state to finish. 'Closed' techniques produce a finished component direct from the upseting machine.
The upsetting axis is usually vertical and the stroke is hydraulically powered. The machines incorporate many features that ensure optimum cycle time, excellent repeatability, quick set-up and reliable operation for all types and sizes of valves.
Forging Screw Press (300 Tn. Upstroke Type) :The scope of the screw press forging is confined to shapes that do not require breakdown operations, or such as have been forged so as to fit the dies. The forging is completed in one stroke or squeeze of the screw. With friction drives there is little danger of jamming the press from an increase in thickness of the flash. These presses do not require any special foundation, as there is no jar or shock in their operation. They make strokes from 10 to 40 per minute and exert pressures from 25 to 1,800 tons.
The screw press may be used for a great variety of hot or cold metal forgings. Besides open die forgings, metals may be extruded through dies, squirted up around the punch or formed in enclosed dies.
Flows between the clamping jaws and anvil plate, heating the exposed portion of the component. The hydraulic cylinder exerts a controlled force on the cold end of the bar producing a shaped head. The material is upset to the required shape via the application of heat, pressure, flow, and linear travel. In 'open' upsetting techniques the component is then passed to a form tool [press] in the red hot state to finish. 'Closed' techniques produce a finished component direct from the upseting machine.
The upsetting axis is usually vertical and the stroke is hydraulically powered. The machines incorporate many features that ensure optimum cycle time, excellent repeatability, quick set-up and reliable operation for all types and sizes of valves.
Heat Treatment Shop : Electric Hardening Furnace (40 K.W. Muffle Type)One of the most important process Engine valve manufacturing is heat-treatment. We have three important machines for the same. Electrical Hardening Muffle type Furnace capable of reaching temperature upto 1200° C is used for Hardening or normalizing process as required.
The furnace is equipped with Continuous Graph Recorder. The advantage of using Electrical furnace over oil fire furnace is uniformity in temperature
Electric Tempering Furnace (15 K.W. with Forced Air Circulation)Electrical Forced Air Circulation Furnace can reach temperatures upto 700
oC & is used for stress-relieving or tempering operations.
Induction Hardening Machines (10 K.W. Capacity)RF 10 KW Induction Heating machine is used for Tip end & Seat Area Hardening. The major advantage of heating by Induction over other methods being it is easier to control case depth along with a very high consistency in results.
Machine Shop : Our machine shop has mainly five categories of machines installed.
Friction Welding Machine : (25 M.M. Capacity)
Bending Straightening Press : (S. P. M. 25 M.M. Capacity)
Turning Lathes :
CNC Turning Machines :- Electronica ECO ELTURN INDIA
- Herbert Husky 1000 U. K.
High Speed Turning Center Lathes :- Hardinge / C. V. A. U. K.
- SECOND OPERATION LATHES: GeeDee Wieler INDIA
- COPY-TURNING MACHINES: Mysore Kirloskar with Ditamir Copy Attach. S. P. M. with Auto-Copy Attach. INDIA.
- GENERAL PURPOSE LATHES : Mysore Kirloskar INDIA
- Herbert 2 - D U. K.
Grinding Machines :- CENTER LESS GRINDER : 24 “ X 12 “ Cincinnati Milacron U. K.
- 14” X 6 “ Hi-Life INDIA
- VALVE SEAT GRINDERS: 14” X 1” Hi-Life INDIA
- 12 “X 1 “ Sukan INDIA
- VALVE TIP GRINDERS: S. P. M. INDIA
- VALVE NECK RADIUS POLISH M / C.: S. P. M. INDIA.
General Machines : Drill M/c., Power Hacksaw, Bench Grinder, Roll Marking M/c., Etc. INDIA.
