|
The Chakan unit is located at Chakan, Amethan Road, Taluka Khed, District Pune, Maharashtra, India. The factory land admeasures approximately 36.5 acres and the factory building consist of total area of approximately 16,500
sq. mtr. The factory building consists of administrative block, press shop, heat treatment shop, tool room, MQC lab, finishing good warehouse, raw material godown, canteen, conference and training facility etc.
MASL has set up a machining shop for which approx 20,000
sq. mtr. has been earmarked.
|
|
Manufacturing Facility
| # |
Press Size |
Weight Range (Kg) |
Typical Parts |
| 1 |
1000 MT |
0.5 to 3.5 |
Con Rod & Cap/Spindle/Steering Arm |
| 2 |
1600 MT |
1 to 9 |
Upper (Control) Arm/Con Rod &
Cap/Crankshaft/Knuckle |
| 3 |
2500 MT |
5 to 12 |
Steering Knuckle/Camshaft/Stub Axle/Con Rod/Links |
| 4 |
3000 MT |
12 to 17 |
Crankshaft/Stub Axle/Camshaft/Knuckle |
| 5 |
5000 MT |
18 to 48 |
Crankshaft/Stub Axle/Steering Knuckle |
Manufacturing Capabilities
-
In-house Tool & Die Development
-
Design Centre - FEA, Delcam, Deform, UG,
AutoCAD
-
Metallurgy Lab - Image Analyser,
Spectrometer, Optical Microscope
-
State-of-the-art Inspection & Testing
Facilities
Press Shop
The Press Shop consists of a wide variety of presses imported from Germany & Russia. The presses in operation are
| 5000T |
- |
1 No. |
|
3000T |
- |
1 No. |
|
2500T |
- |
1 No. |
|
1600T |
- |
1 No. |
|
1000T |
- |
1 No. |
|
|
|
|
|
|
 |
|
 |
|
 |
|
Stub Axle Forging (In Operation) |
|
Stub Axle Forging (In Operation) |
|
Crankshaft Forging (In operation) |
Each of these presses has a computer controlled induction heater and a trim press. Material handling is done by conveyors.
Die Shop
All dies are made in -house using CNC machines, high speed milling machines and EDM Machines. The tool room is backed by a CAD/CAM/CAECentre which provides the design and engineering support.
|
Design & Inspection facilities |
|
Induction Hardening
(In Operation)
&
Die Machining Operation |
 |
|
 |
Computer controlled measurement machine is used to check forgings produced in the shop.
Statistical process control is used extensively in the processes.
Heat Treatment facilities include a new automatic line providing tempered and normalized forgings.
High quality Shot Blasting machines are used in the finishing area to clean the oxidized layer (Scale).
The entire process is certified by BVQI and the unit has been awarded the TS 16949 for its Quality Management Systems.
An Overview of the Machining facility ….
The Machining set-up has strong capability and flexibility in-built for manufacturing products like 4 and 3 cylinder high quality crankshafts, Steering Knuckle and connecting rod for a wide range .
Planned capacity is 275 K Crankshafts , 500 K of Steering knuckles , 250 K sets of Connecting Rods.
|
Crankshaft Machining Operation |
|
Machined Crankshaft :
Inspection & Testing |
 |
|
 |
We have a state of art Crankshaft Machining facility where in we have capability to machine Crankshaft for turbo charger requirements, that is, fillet hardened, as well as naturally aspirated Crankshaft.
In turning module we have Heller Turn-Turn Broach machines for journal and pin turning. These machines facilitate Crankshaft turning with lesser amount of stress induced in the component.
For oil hole drilling operation we are using Makino Make –HMCs with through coolant solid carbide drills with coolant capacity of 70 Bar pressure, to generate burr-free cleaned oil hole galleries.
For induction hardening we are having 225 KW capacity medium frequency machines, with IGBT and CNC controlled fully automatic operation. These help achieve uniform hardness and consistent case depth. The hardening is followed by continuous flow tempering furnace.
The highlight of the post heat treatment, grinding operations is a new generation CBN Journal grinder that we use for main bearing grinding of Crankshaft at 120 m/sec. The machine gives an output quality of 0.25 micron Ra, surface finish on as ground diameters. This machine is totally CNC control including Dressing with multipoint cup dresser. This facilitates the radius blending with the side wall upto 90% .
All grinding machines are provided with Marposs in-process gauging systems as well as Marposs post process gauging systems for inspection of Crankshafts.
To achieve critical positional tolerances of flange holes and dowel holes we have established Makino-HMC with solid Carbides drills and Taps for consistency.
For post-grinding improvement of geometric tolerances (form correction) and surface finish we have installed a super finishing machine with a capability to deliver 2Rt requirements. This is builtt by an IMPCO, USA licensee in India.
Lastly, the pre-packing cleaning of the cranks is carried out on a Specific Hole and General washing machine, to demanding level of Millipore values.
The Process and allied equipment ensures that at every stage of crankshaft manufacturing, it gets validated, ensuring that highest, stringent quality levels are maintained at all times. The facilities are supported with the central Inspection equipments like ADCOL for roundness checking , Counter measurement system for inspection of fillet radius and surface finish parameters , CMM for detailed dimensional measurement, Surface hardness and Micro Hardness Testers.
The manufacturing process is established for ppk ≥1.67
The facility is run by a highly skilled team of specialist engineers and technical staff, having vast experience in manufacturing, machine building and projects. |
