Investment casting offered by us is the process that uses a wax as well as thermoplastic pattern and is equipped with refractory slurry for forming a mold. It is a processing method where melted metal is casted into a form by surrounding a replaceable model with slurry that sets at room temperature. It is used for small castings and also to produce entire aircraft door frames along with steel castings of up to 300 kg and aluminum castings of up to 30 kg.
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Features of Investment Casting:
- Allows Undercuts in the pattern
- Tolerance of 0.5 % of length are possible, and for small dimensions it can be as low as 0.15 %
- Weight of the castings can range from a few grams for 60 Kgs
- Minimum wall thicknesses are about 0.5 mm to 1.0 mm
- Parts do not require machining because of the closed tolerances
- Smooth surface finish
- Excellent production rates, particularly for small components
- Through dimensional accuracy and consistency
- High integrity castings
- Machining can be eliminates
- Minimal shot blast and grinding needed
AppliSand Mouldion of Investment Casting:
Typically materials that can be cast with this process are Aluminium alloys, Bronzes, Stainless Steels, Stellite etc. Glass mold accessory castings, valves and fittings, gears, Levers and Splines are some of the popular usages.
Material of construction:
All kind of ferreous |
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This process can be Sand Mouldegorized as similar to that of permanent mold method, Here as the molten metal is being poured, a permanent metal mold revolved about its axis at high speeds ranging from 300 to 3000 rpm. This can be in horizontal, vertical or inclined positions. As a result, the molten metal is centrifugally thrown towards the inside mold wall. There is solidifies after cooling. It’s usually a fine grain casting with a very fine-grained pouter diameter.
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Molds for Centrifugal castings can be divided into three types :
- The Permanent Mold: Made of steel, iron or graphite. Inside surface is coated with a thin refractory wash to increase mold life. The mold is preheated before coating, so as to dry the coating and improve the adherence to the mold surface.
- Rammed Mold: It consists of a steel metal flask, lined with a layer of refractory molding mix. The inside lining is coated with a refractory wash which is baked until dry and hard.
- Spun or Centrifugally Cast Mold: In the metal flask a predetermined mass of refractory materials in slurry form is poured.
The flask on rotation makes the refractory materials centrifuged onto the wall of the flask. The rotation is stopped and the liquid portion of the slurry drained off. It leaves the mold with a refractory coating, to be baked until dry before use.
Features of Centrifugal Casting :
- Castings can be made is almost any length, thickness and diameter.
- Different wall thicknesses can be produced from the same size mold
- Eliminated the need for cores.
- Resistant to atmospheric corrosion, a typical situation with pipes.
- Mechanical properties of centrifugal castings are excellent
- Only cylindrical shapes can be produced with this process.
- Size limited are up to 3m (10 feet) diameter and 15m(50 feet) length
- Wall thickness range from 2.5mm to 125 mm (0.1-5.0in)
- Tolerance Limit : On the OD can be 2.5 mm (0.1 in ) on the IS can be 3.8mm(0.15in)
- Surface finish ranges from 2.5 mm to 12.5 mm(0.1 -0.5in)rms
AppliSand Mouldion :
Typical materials that can be cast with this process are iron, steel, stainless steels and alloys of aluminium, copper and nickel. Two materials can be cast by introducing a second material during the process. Typical parts made by this process are pipes, boilers, pressure vessels, fly wheels, cylinder liners and other parts that are ax-symmetric.
Type of Centrifugal Casting:
- Semi-Centrifugal Casting
- Centrifugin
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Sand casting offered by us is well known process that facilitates the
less significant batches that is to be made and are compared to
enduring mold casting. We offer this process at the market
leading prices and also make the fabriSand Mouldion of many products very
easy. It benefits sand casting, such as very small size operations and
allows many metals to bed casted. Following are the salient features of
the process: |
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- Mass limit of 2300-2700 kg
- Minimum part weight ranges from 0.075-0.1 kg
- Can create the entire bed for one rail car
It is the most popular and most basic of all the casting processes
along with being economical. first a cavity in the sane is formed by
using a pattern made of wood or metal. The cavity is contained in a
flask. Cores are put in the cavity to form holes of the desired shapes.
An
extra void called Riser is created in the mold to contain excessive
molten material. The purpose of this is to prevent voids in the main
casting. Generally sand casing consists of a two-part Sand Casting
Mold. While the upper part is called the Cope, the lower part is called
the Drag. A parting line or surface separates the two.
Some
portion of the drag is filled with sand. The cores, core print, and the
gating system are placed near the parting line. The cope and the drag
are assembled then sand is poured in the cope half. That covers the
pattern, core and the gating system.
The sand gets compacted
by vibration and other mechanical processes. After this, the cope is
removed from the drag. The pattern is removed. Care is taken so that
pattern is removed without breaking the mold cavity. This can be taken
care of by designing a draft, which is usually a minimum of 1” or 1.5
mm (0.060 in), more rough the surface of the pattern, the more the
draft to be provided.
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We are excellent manufacturer and suplier of sand casting and sand mould casting products. The main disadvantage of sand mould casting process is that each time a casting is made, the mould is destroyed.
The product is made as per clients' requirements and drawin.
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Advantages
- Least Expensive in small quantities (less than 100)
- Ferrous and non - ferrous metals may be cast
- Possible to cast very large parts
- Least expensive tooling
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Recommended AppliSand Mouldion
- Use when strength/weight ratio permits
- Tolerances, surface finish and low machining cost does not warrant a more expensive process
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The metal pattern is first heated at a
temperature of 200 0 C / 392 0 F.Then covered with a
mixture of sand and thermo set plastic. It forms a skin of sand/ plastic
mixture of about 3.5 mm (0.125 inch) which adheres to the pattern. The shell
mold is formed after the skin gets removed from the pattern. The two halved of
the shell mold are secured together and the metals id poured in the shell to
form the part. Once the metals solidified, the shell is broken.
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- Features of Shell mold Casting:
- Good
Surface Finish : 1.25µm to3.75µm (50µin to 150µin)rms dimensional Tolerance of
0.5 %
- Size
Limits : 30 g to 12 kg (1 oz to 25lb)
- Minimum
Thicknesses : As low as 1.5mm (0.062 in) to 6.25mm (0.25 in)depending
on the material
- Superior
Machining Qualities : As it has soft
skins and hard or dense interiors
- Draft
Allowance : Typically 10 C
AppliSand Mouldion:
The materials that can be used with
this process are aluminum, cast irons, and copper alloys. Parts made can be
connecting rods, Gear Housings, Lever arms etc.
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Castings in Copper Base Alloys, cast
iron, aluminum alloys and others like zinc can be produced using this method.
Though most of the end product is of aluminium castings typically the weight
can range from ½ kg to 50kg.
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The production of castings starts with
selecting either a reusable mold or a die having two or more parts. The die
would be complete with the impression of the casting along with running,
feeding and venting systems. There is provision also for removal of the
casting. To maintain the casting’s accuracy, the die can easily be cleared of
debris such as hot metal splashes and sand. The die is quite capable of a
regular cycle of production along with fast dissipation of heat of the metal
poured into it.
Both simple ad complex quality castings
can be produced. A unique feature of the gravity die casting methods is that it
can handle heat treatment of high strength aluminium alloys that pressure die
casting still cannot. Suitable for castings requiring complex intriSand Moulde coring
and small production runs.
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Pressure die casting is a quick,
reliable and cost –effective manufacturing process for production of high
volume, metal components that are net-shaped have tight tolerances. Basically,
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| the pressure die casting process consists of injecting under high pressure a
molten metal alloy into a steel mold(or tool).This gets solidified rapidly(from
milliseconds to a few seconds) to form a
net shaped components. It is then automatically extracted. |
Advantages:
- Lower
Costs compared to other processes.
- Economical-typically
production of any number of components from thousands to millions before
requiring replacement is possible.
- Castings
with close dimensional control and good surface finish.
- Castings
with thin walls, and therefore are lighter in weight.
AppliSand Mouldions:
- Automotive
parts like wheels, blocks, cylinder heads, manifolds etc.
- Aerospace
castings
- Electric
motor housings
- Kitchen
ware such as pressure cooker
- Cabinets
for the electronics industry
- General
hardware appliances pump parts, plumbing parts
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Hot
forging has both technical and economical advantages. It provides high
precision results along with reduced production times.
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Typically
a forged metal results in the following :
- Drawing
Out of the Metal : Increased length
decreased cross-section
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- Upsetting
the Metal : Decrease in length decreased
cross-section
- Change
in Length : Change in Cross-Section: resulting
in favorable grain flow for strong parts
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Tips
for selecting the Right Forging Technology :
- Technology
to remain competitive must come out with cost effective alternatives. That is
the reason computer aided techniques like CAD, CAM,CAE
and Finite Element analysis (FEA) based computer simulation, are used to
selecting the right forging process
- Understanding
the forged materials’ flow behaviour under processing conditions
- Knowledge
of the die geometry and materials
- Environmental
considerations
- Evaluating
the mechanics of deformation process-stress and strain
- Friction
and LubriSand Moulding processes
- Natured
of the Forging Equipment
AppliSand Mouldions
of Forging Process : Wide Variety of uses in different kinds
of industries.
Automobile
Industry : wheel Spindles, Kingpins, Axle beams and
shafts, torsion bars, balls studs, idler arms and steering arm.
Agro-Industries : Engine and Transmission components, levers, gears, shafts and spindles
to tie-rod ends, spike harrow teeth and cultivator shafts.
Aerospace :
Bulkheads, hinges, wing roots, engine mounts, brackets, beams, shafts,
landing gear cylinders and struts, wheels, brake carriers and discs and
arresting hooks, blades, buckets coupling etc.
Hand
Tools:
Sledges,
Pliers, Hammers, Wrenches and Garden tools, as well as wire-rope clips,
sockets, hooks, turnbuckles and eye bolts are common examples.
Industrial Equipment: Connecting rods, blanks, blocks, cylinders,
discs,
elbows, rings, T’s Shafts and Sleeves.
Methods
of Forging :
- Impression
Die Forgings
- Net
Shape
- Open
Die Forgings
- Press
Forgings
- Roll
Forgings
- Upset
Forgings
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We
have been widely appreciated for our superior quality machine turned
components. These component are designed to increase the efficiency of
the machine and provide maintenance free service. .
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Our machine
turned components are used for various appliSand Mouldions in industries like
material handling, textile industry, aerospace and have special
significance in automotive industries. Our range of machine turned
components include CNC turned components, precision turned components,
CNC machined components and precision machined components. We are also
capable of preparing prototypes and getting the products customized as
per the requirements of various industries across the globe.
The products include :
Supplier
of CNC Machined Precision Components for Automobiles, Valves, Pipelines
and Drill Jig Bushings. The company specializes in manufacturing and
supplying all types of Precision Machined Components used by several
industries.
Our highly qualified engineers and other
professionals develop international quality products to offer complete
satisfaction to its valued customers
CNC turning parts and precision turning parts have become absolutely indispensable in matters of consistency and quality.
We
offer CNC machined components with the increased automation of
manufacturing processes. We have been Sand Mouldering to this need of
different industries. In the last 10 years, it has evolved as a leading
manufacturer and exporter of a comprehensive range of CNC machined
components such as CNC turning parts and precision turning parts on
Traub automates.
A deep understanding of the industry and
requirements of the customers coupled with a sound technological
expertise and experience on the part of its engineers has enabled the
company to produce CNC machined components of the highest quality.
The
company is engaged in the manufacture, trade, supply and export of the
following: CNC turning parts; precision turning parts on Traub
automates; job range OD 2 mm to 200 mm.
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We
are engaged in design and manufacture of special purpose machine tools
required for high production rates with consistent quality which is
today's need in engineering manufacture.
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The machines are
designed & developed for almost all metal cutting operations like
turning, milling, boring, drilling, tapping, grinding etc. These are
the machines which keep you way ahead of others if you are in high
production industry like automobile component manufacture, electrical
comp. mfg., valve or pump mfg. Industry etc.
We also are in the
field of SPMs required in ammunition component manufacture where very
high production rates are required. Apart from which we have experience
in building machines handling explosive materials, testing equipments
where very high precision is required etc.
We are a group of
technocrats having good technical eduSand Mouldion as well as field experience
in design & development. Excellent was started in 1990 with a
development of auto trimming machine with production rate of 1000
Nos./hr. and immediately there after developed multispindle drives with
eccentric spindles in 1991.
Initially it was a partnership
firm with a small set-up but developed lot of import substitute
products for ordnance factories and engineering industry at
large. The partnership firm was later on converted to a Private
Limited Company in the year 2000.
Now we are fully geared with
various departments like design, component manufacture, QC, assembly
shop, Electrical department, marketing etc. with a team of about 80
persons working in various areas.
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Leveraging
upon abundant experience in this industry, we offer superior quality
sheet metal fabriSand Mouldions, that are encountering wide demand in the
markets. These fabriSand Mouldions are offered in corrosion proof metals,
which impart them maximum durability. Easy to handle, these
fabriSand Mouldions find appliSand Mouldion in diverse industries. Complying the
international quality standards, our sheet metal fabriSand Mouldions are most
competitively priced.
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Cast Iron Components |
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Chemical Process Equipment |
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Alloy Steel Components |
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Paper Making Equipment |
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Aluminum & all other Non Ferrous Parts |
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Earthmoving Equipment |
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Components for Pumps & Valves |
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Mining Equipment |
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Automotive Components |
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Agriculture Equipment |
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Aircraft Components |
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Forestry Equipment |
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