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    Sandhar Bawal Unit - 1

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    Ankush Sood
    Sandhar Components Bawal Unit-I designs and develops high pressure die cast aluminum automotive parts. The plant visited includes departments for new product development, machine shops, die casting, machining, painting, and packaging. Key customers include TVS Motors, Royal Enfield, and Yamaha Motors. The plant uses cold chamber die casting machines, CNC machining, and paints parts using an automotive primer and base coat process to produce finished goods for automotive OEMs.

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    Sandhar Bawal Unit - 1

    Uploaded by

    Ankush Sood
    51 views6 pages
    Sandhar Components Bawal Unit-I designs and develops high pressure die cast aluminum automotive parts. The plant visited includes departments for new product development, machine shops, die casting, machining, painting, and packaging. Key customers include TVS Motors, Royal Enfield, and Yamaha Motors. The plant uses cold chamber die casting machines, CNC machining, and paints parts using an automotive primer and base coat process to produce finished goods for automotive OEMs.

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    SANDHAR BAWAL UNIT _1 Visit

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    SANDHAR BAWAL UNIT _1

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    Sandhar Components Bawal Unit-I designs and develops high pressure die cast aluminum automotive parts. The plant visited includes departments for new product development, machine shops, die casting, machining, painting, and packaging. Key customers include TVS Motors, Royal Enfield, and Yamaha Motors. The plant uses cold chamber die casting machines, CNC machining, and paints parts using an automotive primer and base coat process to produce finished goods for automotive OEMs.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    51 views6 pages

    Sandhar Bawal Unit - 1

    Uploaded by

    Ankush Sood
    Sandhar Components Bawal Unit-I designs and develops high pressure die cast aluminum automotive parts. The plant visited includes departments for new product development, machine shops, die casting, machining, painting, and packaging. Key customers include TVS Motors, Royal Enfield, and Yamaha Motors. The plant uses cold chamber die casting machines, CNC machining, and paints parts using an automotive primer and base coat process to produce finished goods for automotive OEMs.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    SANDHAR COMPONENTS BAWAL Unit-I

    Plant visit - 3

    Report submitted by :- Ankush Sood


    SANDHAR COMPONENTS BAWAL UNIT-I
    On 18th march 2019 we started our third plant visit i.e. Sandhar Technologies Bawal
    Unit – I, Mr Ajay ragav is plant head of Bawal Unit –I. This plant is started in 2011.
    At first we meet with Deputy general manager Mr.V.K Yadav, he elaborate the plant
    layout in brief, They Design and develop the high pressure die casting, about 45 % of
    business comes from TVS Motors, 10-20% comes from non-automotive company i.e.
    Havel’s , other customer are Royal Enfield and Yamaha motors.Our visit was held
    under the supervision of Mr. Gurjot and Akshit.

    Department we visited:-

    1. NEW PRODUCT AND DEVELOPMENT


    2. MACHINE SHOP-1
    3. PRESSURE DIE CASTING DEPARTMENT
    4. MACHINE SHOP-2
    5. PAINT SHOP
    6. PACKAGING DEPARTMENT
    NEW PRODUCT AND DEVELOPMENT:-

    First drawing is received through customer and then NPD team inspects the part
    drawing thoroughly weather it is permissible range of manufacturing or not. After that
    they started tool design of part. UG Nx software is used to prepare CAD model for
    tool design. After the designing they will do outsource Mold Flow Analysis of Tool.

    Two type of Aluminum grade is used in this Unit :-

    1. ADC-12
    Aluminum alloys (ADC12) consist of Aluminum - Copper - Silicon have high
    mechanical properties and good castability, so these alloys have been used for
    automotive parts with complicated shapes, e.g.:- Crank Case, Clutch Hub,
    Break drum hub and lighting panel.
    2. ADC-6
    It is also an Aluminum alloys (ADC6) consist of Aluminum - Magnesium
    which offer good corrosion resistance. However, these alloys do not have high
    castability that’s the main reason ADC-6 have less application. Mainly used
    for foot rest part.

    MACHINE SHOP:-

    Al Die Molds are prepared in Machine shop-1 with the help of CNC machines and
    non-traditional machining. They outsource the Mold-base and do only core and cavity
    machining In-house only.
    Delcam is the software used by CNC programmer, at first they do rough machining
    on core & cavity and send it for Case Harding upto 46-48 hrc, and then do the final
    machining. Carbide cutting tools are used for machining.

    Material used for Core and Cavity: - Hot die Steel (This alloy is one of the Hot Work,
    Chromium type tool steels which contains molybdenum and vanadium as
    strengthening agents)

    The following machine we saw at Machine Shop-1

     CNC MACHINE

     EDM MACHINE

     WIRE CUT MACHINE

     EDM DRILL MACHINE

    CNC MACHINE- CNC, machines are operated via numerical control program. The
    language behind CNC machining is G-code (stands for motion of tool path) and
    M-code (stands Machine code such as coolant, tool changes etc.)
    EDM MACHINE- Electro Discharge Machining (EDM) is a non-traditional
    machining process, whereas electrical energy is used to generate electrical spark and
    material remove due to the spark energy. EDM is basically used for machined
    difficult geometries which are not possible with CNC machines.

    Two type of Electrode is used in EDM machine:-


     Copper (for good surface finish & useful in small cavity where it is difficult to
    polish)
     Graphite (for extremely fine and superior surface finish, easy to machine)

    Sparkonix EDM is used by Bawal Plant.

    WIRECUT MACHINE- It is also a non-traditional machining process, Here a thin


    metal wire (mainly brass having Ø0.25 mm) is fed through the pre-hole workpiece
    and submerged in a tank of dielectric fluid. Wire-cut EDM is typically used to cut
    plates as thick as 300mm to make tools, and punches for dies from hard metals that
    are difficult to machine with other methods.

    Sodick fixed jet wirecut machine is used by them.

    EDM DRILL MACHINE- EDM Drilling machine used to drill micro holes having
    more than 200 mm depth by a thin Brass electrode (dia upto 0.1 mm) at a very high
    speed those are difficult to machine with other methods.

    PRESSURE DIE CASTING DEPARTMENT:-

    In casting department there is a big tower furnace (Furnteck's tower furnace having
    capacity 2 ton) to melt aluminum ingot for die casting machines. This big furnace is
    shut down only when if there is a more than 48 hours or two days holiday otherwise
    they will run it 24 hours a day because the consumption of electricity to start the
    furnace until the metal is melt is very high. The temperature they maintained is about
    750°c.

    Degassing of Aluminium-

    Before using the melted aluminium there will be a degassing process, used to remove
    impurities from molten metal. Because when aluminium is casted there will be some
    impurities which can create weak points in the product so it is necessary to do
    degassing of aluminium.
    Process: - It’s a rotating impeller of graphite from which nitrogen gas is passed in to
    the liquid aluminium, Nitrogen carried the impurities in the form of bubbles. Argon is
    also effective, but because of high cost nitrogen is preferred.

    They also reused the material with 60/40 ratio and verified material properties by a
    butter sample. Procedure for butter sample is :-
    First molten metal is poured in a butter sample cavity and placed it into the Vacuum
    chamber. After solidifying the butter sample if it shows concave top face it is reusable
    otherwise not. Because in concave face of butter sample, there is no such impurities in
    the molten metal.

    OK Sample NOT OK Sample

    There is 20 Cold chamber die casting machine varying with tonnage capacity from
    120 to 530. All die casting machines are rrobotic arms to handle molten metal.

    Process- It is a metal casting process that is characterized by forcing molten metal


    under the high pressure into a mold cavity.The products obtained from casting are
    unfinished and oversize.

    MACHINE SHOP -2 :-

    After casting, Parts are need to be machined to provide smooth sealing surfaces,
    threading and fitment diameters and holes as per drawing. In the machine shop cast
    part to be machine is a biggest challenge to them for meeting the customer
    specification.
    For machining them, they used 7 SPM (Special purpose machine) and 3 CNC
    machine.

    Before send to the pain shop, Part goes with Shot Blasting process. It is a surface
    treatment process using high velocity steel abrasive. It is used for a surface protection
    and also prior-preparation of surfaces prior to further processing, such as welding,
    coloring, etc.
    PAINT SHOP: Chain conveyor mechanisms were used to handle the components.
    Products are painted manually with the help of sprayers operated by air compressors.

    The primer is the first coat to be applied used for protects the vehicle from corrosion
    and improves ease of application by making it easier for paints to stick to the surface.

    The base coat is applied after the primer coat. This coat contains the visual properties
    of color and effects. They used automotive based Nerolac paint

    If necessary third coat is sprayed on top of a colored basecoat, third coat is a glossy
    and transparent coating that forms the final interface with the environment. For this
    reason, this coat must be durable enough to resist abrasion and chemically stable
    enough to withstand UV light.

    PRE-DISPATCH INSPECTION AND PACKING DEPARTMENT:-

    Finally finished and painted products are packed here and once again critical
    parameters of finished goods are checked by pressure gauge. After packing goods are
    sent to storage unit in order to dispatch to the customers as per their orders.

    KEY LEARNINGS AFTER VISITING BAWAL UNIT -I

    1. Know about degassing of aluminium and how check reuse aluminium


    properties.
    2. How to paint automotive parts.

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