Casting India Rathinapuri, Coimbatore, Tamil Nadu

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. 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.

We offer shellmould casting. Features of shell mould casting: good surface finish : 1.25µm to3.75µm (50µin to 150µin)rms dimensional to- -lerance 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) de- -pending on the material superi or machining qualities : as it has soft skins and hard or dense interiors draft allowance : typically 10 c

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.

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. 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.

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

We offer high grade of sheet metal fabrication through our cutting edge technology. Our specialization lies in fabrication of stainless steel and other metals. Our fabricated products are used in various metal working and comprises of the following types.

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. 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 Recommended AppliSand Mouldion    Use when strength/weight ratio permits    Tolerances, surface finish and low machining cost does not warrant a more expensive process

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: Mass limit of 2300-2700 kg Minimum part weight ranges from 0.075-0.1 kg Can create the entire bed for one rail carIt 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.

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,  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  

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. 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

Hot forging has both technical and economical advantages. It provides high precision results along with reduced production times. Typically a forged metal results in the following : Drawing Out of the Metal : Increased length decreased cross-section Upsetting the Metal : Decrease in length decreased cross-section Change in Length : Change in Cross-Section: resulting in favorable grain flow for strong parts 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

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 he 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.

We offer froging process. Applications 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.

We offer extrusion casting. Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes is its ability to create very complex cross-sections and work materials that are brittle, because the material only encounters compressive and shear stresses.

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. . 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 customersCNC 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.

We offer CNC machined components with the increased automation of manufacturing processes. We have been catering 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.

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. 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

We are engaged in manufacturing and exporting a premium range of different castings, which are fabricated in accordance with the global casting standards and specifications. Successfully catering to several industries, our castings are extensively used in meeting the operating demands of different industrial processes. Our range includes pressed components, die casting tools, sheet metal pressed components, pressure die casting tools, Investment Casting, Sand Casting, Shell Mould Casting, Centrifugal Casting, Gravity Die Casting, Pressure Die Casting, Forging Process, Ceramic Mold Casting, Extrusion Process, Full Mold Casting, Permanent Mold Casting and Plaster Mold Casting.

Feature : Dimension accuracy,High asthetic value etc.