vALVE
BODY FORGINGS
Technology/Process Description:
The
company manufactures high precision forgings for Defence, specialized forgings
for Aero & Space Research, heavy forgings for Commercial Vehicles and other
spares for light Automobiles etc..Main production machinery comprises a 10 Ton and 6 Ton closed die pneumatic forge hammers with an
annual capacity of 7500 Metric Tons of carbon and alloy steel, non-ferrous,
special metals viz. Titanium & Nickel Base alloys, Stainless steel etc..
The Supporting Machinery consist of Billet Shearing machines, 1000 Tons &
600 Tons trimming presses, Electric & Oil fired furnaces for heat treatment
and billet heating, shot blasting machines etc. There is a modern heat
treatment plant equipped with number of furnaces both LDO fired and
electrically heated and a charging machine which takes care of loading and
unloading of heat treatment charges.
SIFL's
design & engineering capabilities are ably backed by a well equipped Die
Shop, set up along modern lines with Double Spindle Copy Milling Machines,
Spark erosion die sinking machines, Radial Drilling machines, Plano millers,
lathes, Tool & cutter grinders, etc. The design and development of the die
holds the key to blemish-free forgings.
SIFL designs both single-impression and multi-impression dies. The
design, of course, is related to the forging drawings. And the decision on the
type of die to be used is based on the specific requirement of each case. The
care that goes into the design of each die also goes into the selection of raw
materials and the sequence of operation that follows.
Heat Treatment Facility
The billets
for forging are heated in oil fired or electric furnaces, closely controlling
the temperature to reduce the scale formation and overheating so that the metallurgical
properties are ensured in the final product .In addition, in-process inspection
is carried out at all stages viz at forging stage and cent percent inspection
for visual defects after forging. The accepted forgings are duly heat treated.
By providing heat treatment services in-house, SIFL is able to maintain greater
control over heat treating process. The facility comprise batch furnaces both
oil fired & electrical, continuous electrical heating furnaces, etc. to
carry out annealing, normalizing, hardening, tempering, iso-thermal annealing,
etc. or other operations as specified by our customer.
Close
temperature control and process monitoring with the help of temperature
recorders ensures uniform properties duly supported by evaluation of metallurgical
properties through representative test pieces.
Testing
Surface
conditioning is done by shot blasting/grinding and final inspection is carried
out once again to ensure quality requirements. Stage-wise inspection
non-conformities are taken care of by timely corrective and preventive action.
SIFL has set up a system of total quality control consisting of an array of
state-of-the-art specialty equipments where products go through a series of
rigorous tests, the destructive test including tensile, impact testing, wet
analysis, carbon-sulphur determination, metallography and non-destructive tests
using Ultrasonic flaw detection, Magnaflux crack detection, Die Penetrant...
tests that ensures quality. Setting and control of quality standards at all
stages right from the receipt of raw material to the finished product through
quality plan makes us deliver superior quality forgings with close dimensional
tolerances and metallurgical properties.
Technology/Product Specifications:
PRODUCT: VALVE BODY FORGINGS
·
For
Aero Space and Research Sector
1.
Impellers
2.
Nozzle
Domes
3.
Vehicle
Support Blocks
4.
Rings
& Vanes
5.
Cone
Forgings
·
For
Agriculture
1.
Crankshafts
2.
Gears
3.
Pinions
· For Automobile Sector
1.
Axle
Arms
2.
Front
Hubs
3.
Diff
Cages
4.
Stub
Axels
5.
Couplings
6.
Crownwheels
·
Defence
Sector
1.
Knuckle
Forgings
2.
RAFD
Housings
3.
Special
Alloy Forgings
4.
Flanges
5.
Gears
·
Earth
Moving Sector
1.
Tooths
2.
Shafts
3.
Pinions
4.
Rollers
5.
Gears
6.
Connecting
Rods
7.
Crankshafts
·
Heavy
Engineering Sector
1.
Motor
Housings
2.
Valve
Bodies
3.
Choke
Bodies
4.
Fly
Wheels
5.
Sprocket
hubs
6.
Crankshafts
7.
Gears
& Pinions
·
Railways
Sector
1.
Connecting
Rods
2.
Bearing
Caps
3.
Gears
4.
Pinions
5.
Draw
Hooks
6.
L.S.
Seats
7.
Guide
8.
Central
Pivot Pin
Company Profile
|
Company Name |
Steel & Industrial Forgings
Ltd. |
|
Address |
Athani.P.O.,Mulangunnathukavu,Thrissur-680771,Kerala |
|
Contact person |
CDR(RETD.)K.Shamsuddin |
|
Phone |
+91-487-2201736 |
|
Fax |
+91-487-2201753 |
|
E-mail |
|
|
Web Site |
|
|
Year of Establishment |
1983 |
|
Product(s) Manufactured |
Forgings-Valve Body, Gear
Connecting Rod, Crankshaft |
|
Production (FY-05) (Products contributing
most to the sales) |
Closed Die Forgings 2486 MT |
|
Sales Turnover |
FY 05: USD 7 Mn FY 04: USD 5.3 Mn FY 03: USD 4.5 Mn |
|
Conformity to Standards |
Indian |
|
Compliance to ISO |
ISO 9001:2000 |
|
Foreign Collaboration |
Nil |
|
Manpower Total (Nos.) |
260 |
|
Raw Materials / Equipment used |
·
Carbon
& Alloy Steel ·
Non
Ferrous Special Metals ·
Stainless
Steel ·
Nickel
Base Alloys ·
Billet
Shearing Machine ·
Trimming
Presses ·
Electric
and Oil fired Furnaces ·
Shot
Blasting Machines |
|
Effluent Generated |
Non Polluting |
Broad Profile of Project
Offer
|
Project |
To Manufacture Valve Body Forgings |
|
Capacity per Annum |
2500 MT |
|
Land Requirements/ Building Requirements |
1000 Sq.M |
|
Plant & Machinery and Test Equipment |
·
Billet
Shearing Machine ·
Trimming
Presses ·
Electric
and Oil fired Furnaces ·
Shot
Blasting Machines ·
Billet
Heating ·
Ultrasonic
Flaw Detection ·
Magnaflux
Crack Detection ·
Die
Penetrant |
|
Electrical Installation |
200 |
|
Implementation Period |
8 Months |
|
Manpower Required |
260 |
|
Raw Materials / Equipment Required |
·
Carbon
& Alloy Steel ·
Non
Ferrous Special Metals ·
Stainless
Steel ·
Nickel
Base Alloys ·
Billet
Shearing Machine ·
Trimming
Presses ·
Electric
and Oil fired Furnaces ·
Shot
Blasting Machines |
|
Total Project Cost |
USD 2.5 Mn (Approx.) |
|
Expected Annual Sales |
USD 1 Mn |
|
Profitability |
10 % |
|
Form of Offer |
Turnkey Project |