Cast Iron & SG Iron Casting Facilities
Machine Shops
Investment Casting
Cast Iron & SG Iron Casting Facilities
Sand Casting
Sand casting is the most versatile among the manufacturing methods and gives the Engineers the freedom to design complex parts from unlimited number of metals and alloys.Sand casting is a manufacturing process where the molten metal is poured into the expendable sand mould cavity either by gravity or by force, where it solidifies to form the cavity shape. 3D object formed by this process is also called casting. Most common sand castings include Engine blocks, cylinder heads etc.
- Sand casting can be used to make virtually any size part from a gun trigger to an engine block – it is not restricted by the desired part size if the right mould is fabricated
- Sand casting can create very complex parts if the correct cores/gating systems are used
- The process is highly adaptable and can be implemented in the mass production of parts
- Almost all types of alloys can be cast, as long as they melt and are pourable
Sand Casting Infrastructure
- Moulding sand is prepared in a fully automated sand plant which is equipped with a 500Kg Mixer. This plant delivers prepared sand meeting all the stringent parameters for moulding at the rate of almost 32 tonnes per hour.
- DISA ARPA 450 and 300 Simultaneous jolt squeeze machines are used for moulding along with manual moulding for castings from 7Kgs up to 350Kgs.
- Inductotherm variable induction power, high frequency melting system with crucible sizes of 750 kgs. and 500 kgs. delivers the right molten metal at the desired temperature for pouring.
- Cupola furnace with melting capacity of 3.5 Tonnes per hour is used to cast Grade 20 CI Castings.
- Other allied facilities available in the foundry are SG iron Castings, pouring ladles, shot blasting machines (Hanger Type),SUSHA Core Shooter shop, fettling , grinding and paint Shop.
Sand Casting Technical Details
Moulding Lines
| ARPA 450 (Make DISA) | ARPA 300 (Make DISA) | WHPL 1 & 3 | |
|---|---|---|---|
| Box Size (MM) | 610 x 610 | 610 x 445 | |
| Weight Range (In Kg) | 40 to 100 | 7 to 40 | 40 to 80 |
| Mould Rate / Hour | 35 | 45 | 30 |
Core Shop Core Shell Shooters
| Machine | Count | Make | Plate Size |
|---|---|---|---|
| Shell Core Shooters (Vertical Parted) | 4 | Susha Conventional | 15″ x 12″ |
| Shell Core Shooters (Vertical Parted) | 1 | Susha Automatic | 15″ x 12″ |
- Single Directional Flow for Head Core Assemblies
- Gas Fired (Dual Fuel – LPG / Bio Gas) Core Ovens. We have both Continuous & Batch Ovens.
- Core Storage & Handling System.
Melting Furnaces
| S.No. | Machine | Count | Make | Melting Capacity |
|---|---|---|---|---|
| 1 | High Frequency Induction Furnace | 2 | Inductotherm | 750 Kg |
| 2 | High Frequency Induction Furnace | 1 | Inductotherm | 500 Kg |
| 3 | Cupola Furnace | 1 | – | 3,500 Kg/Hr |
- Fume Extraction System
- Spectrometer & Spectra-View to check and display online chemistry.
Machine Shops
Tool Room
Tool-Room is the backbone of casting industry. We have a well equipped tool room consisting of a professional pattern shop, milling machines, test benches and test lab. A CAD/CAM research and development centre focussed on development of new products and machining, repair and inspection of DIES and Patterns for our castings and other products.
CNC Machine Shop
Our machine shop is fully equipped with CNC machines and all our LINTAS PRODUCTS are machined in house. Turning centres includes machines from reputed companies like Doosan, Ace, LMW with Fanuc controls. Vertical Machining Centres are of makes like DOOSAN and FANUC(ROBO-DRILL). Achieving the desired tolerances in microns, surface finishes, positional accuracies and other geometrical dimensional requirements are our strength.
Patterns, Dies and match plates are also manufactured In-House under very strict supervision thereby giving us the advantage of desired dimensions, finish and timely development.
Conventional Machine Shop Assembly Line
We have a fully customised conventional machine shop for machining of LINTAS Brand Diesel engine spares. The Machine shop consists of several special purpose machines with customised lathe beds and tool posts, hydraulic boring machine, drilling centre, milling machines.
The layout is professionally designed to allow for proper flow of job avoiding any backward flow of materials.
Investment Casting
Intro
Investment casting, also known as precision casting or lost-wax casting, is a manufacturing process in which a wax pattern is used to shape a disposable ceramic mould. A wax pattern is made in the exact shape of the item to be cast. This pattern is coated with a refractory ceramic material. Once the ceramic material is hardened, it is turned upside-down and heated until the wax melts and drains out. The hardened ceramic shell becomes an expendable investment mould. Molten metal is poured into the mould and is left to cool. The metal casting is then broken from of the spent mould.
These process qualities can provide net shape or near-net shape castings, which provide customers with significant cost savings in material, labor, and machining. It can make use of most common metals, including aluminium, bronze, magnesium, carbon steel, and stainless steel. Parts manufactured with investment casting include turbine blades, medical equipment, firearm components, gears, jewellery, golf club heads, and many other machine components with complex geometry.
Our team works collaboratively with clients to design the pattern and moulding method for each custom casting.
Request a Quote to get more information on how our casting service can match your project requirements.
Manufacturing Capabilities in Investment Casting
Single Piece Weight – 40 Grams to 20 Kg for Stainless Steel
| Process | Machine | Make | Capacity / No. of Machines |
|---|---|---|---|
| Wax Moulding | Injection Moulding | Modtech | 3 |
| Melting | Induction Furnace | Inductotherm | 150 Kg Dual Track |
| Dewaxing | Autoclave | Bernard | 150 Shells / Hour |
| Surface Finish Treatment | Shot Blast Machine | Mera, Belt Tumble Type | 2 |
| Shell Baking | Shell Fire, LPG Powered | – | Matches Melting Capacity |
| Dewaxing | Boiler | Long-Life |
