Molding
Molding is one of the beginning process of the casting. Aluminum patterns are used to form cavity as per design. Core is inserted in the cavity to create hollow sections for ventilated disc/rotor.
Melting
As per customer material requirement charge is prepared. We have two 500 kg medium frequency induction furnace. Induction melting is mainly used for critical quality material requirements in chemical, physical and microstructure properties.
Pouring
Molten material is poured in cavity to get the required structure. Pouring process is done in two-stage big ladle pouring and industrial pouring according to product weight. Some additives are also added during pouring to get defect free casting.
Sand Casting
As material solidifies it adopt the shape of cavity and hollow sections are formed in vented dics. Shot blasting is done to clear the surface of cast product.
CNC Machining
We perform facing operation on both sides of disc/rotor in CNC machine, which is computerized control machine, gives high accuracy in dimensional and geometrical parameters. A main benefit of CNC Facing is to minimize cycle time, repeatability of quality and consistency in product.
Grinding
Grinding is the process where super surface finish can be maintained on products. Surface of Disc/rotor are grinded to create effective frictional surface for braking and ensure tight machining tolerance for Disc Thickness Variation (DTV).
VMC Machining
Holes for wheel hub, studs/bolt and mounting bolt for disc are drilled in VMC machine, which gives high accuracy in dimensional parameter.
Dynamic Balancing
Brake disc/rotor rotates at very high speed in vehicle and slight unbalance mass can lead unpleasant ride and compromise to safety so, disc/rotors are dynamically balanced in automatic balancing machine by removing excess material from non-functional surface.
Stage Inspection
Our quality pillars are to ensure that product is ready to support the most demanding applications with zero defect in any aspect. During production a qualified team of inspectors continuously check products each stage by stage round the clock to find out any kinds of deviation that they think might have occurred during machining which is most necessary to be resolved before finishing of production.
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