An ISO/TS 16949:2009, PED 2014/68/EU & AD2000-Merkblatt W0 Certified Company

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Process

ENGINEERING & DESIGN..

  • Well equipped with 2D-3D design software
  • Centralized control of engineering documents to access easily all Departments..
  • Awaited of Forging Simulation Software.

DIE MANUFACTURING & INSPECTION

  • Using Dies material DIN-2714 for closed die forging & H11/H13 for press forging. Hardness: 38-42 HRC
  • Dies for Forging, Trimming die-Punch & Cold Coining are sinking on VMC.
  • Finished Impression of Die is 100% dimensionally checked by LAYOUT INSPECTION on Plaster of Paris (POP) mould.
  • By POP mould, Prepare hard facing trimming die edge & Verify Punch dimensions.

IN HOUSE RAW MATERIAL TESTING

  • Chemical Analysis is done by Spectrometer. Make: SpectroMaxx - Germany
  • Other testing facility available like Micro cleanliness, Inclusions, Hardness, step-down test, Jominy end quenched Grain flow , Mechanical Test etc.
  • Metallurgical Microscope with Image Analyzer software available to check Micro structure, Grain size after Heat treatment.
  • Steel round & square are material identified by Heat code & color code on both end along the length to avoid mix-up.
  • Always prepared AL or Si Killed material from OEMs approved sources Like Aarti, Remi Metal, Kalyani, Sunflage, Adhunik, Bhushan Power & steel, JSW, Gerdau etc.

BLANK CUTTING

  • Cut blanks are done on high productive precise circular saw machine with auto loader facility, Billet shearing machine & band saw.

HEATING

  • Cut blanks are heated by Induction billet heat in Press forging, Controlled Temperature Oil fired furnace for Hammer forging & Induction Metal gathering machine for Upset forging. Temp.: 1150-1250 Cel.

FORGING

  • Forgings operations are performed with hammers & presses includes bending, drawing down, upsetting, rolling which execute in one heating cycle to gather with finish forging.
  • Subsequent Trimming operation to remove excess material is done on Power Press.

IN HOUSE HEATTREATMENT

  • Forging undergoes Normalizing, Annealing, Stress relieving as per Validate Temperature & time cycle.
  • Heat treatment cycle are recorded & controlled using PLC based micro processor.
  • Continuous Heat treatment furnace with Quenched-Tempered, Iso-annealing facilities.

POST OPERATION-SHOT BLASTING & FETTLING

  • Forging surface De-scaling operation is done by Tumbler type shot blasting machine.
  • Using proper grade of shots (0.45 & 0.55mm) to avoid pit marks & embossed marking.
  • 100% fettling is done for flash projection, burr, chopping etc.

CRACK DETECTION – HARDNESS & QUALITY INSPECTION

  • 100% Magnetic Partial Test (MPI) is done for all functionally critical forging OR Customer requirements.
  • Hardness is checked by Brinell Hardness tester for 3000kg load & 10mm ball dia.
  • 100% visual inspection is done after shot blasting. Pre-dispatch Inspection report (PDI) report is carried & sends to customer along material.

CNC MACHINING...PENTAGON FORGE & MACHINE LTD.

  • Well equipped CNC-VMC machine along with rotary tilting table facility available for ready to use or assembled components.
  • Coordinate Measuring Machine (CMM)- ACCURATE(SPECTRA) & Surface Hardness tester-MITUTOYO available for Precision component Measurement & testing.
  • In house standard room for calibration facility.
  • Marking machine for traceability.
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