Infrastructure

In P.C.Sons Castings we are committed to achieving excellence in the quality of its product and services to its market. Our technical ingenuity has provided cast iron solutions since 1980. We utilize multiple technological resources to enhance
our products and services.

The Foundry has a built-up area of 75,000 Sq.ft. Constructed in total land area of Five Acres. The Foundry is well equipped in the areas of Molding, Core Shop, Fettling, and Quality & Testing. The detailed list of Equipment's installed is enclosed

Cast Iron & Ductile Iron castings are produced for applications requiring strength, durability, good machinability and low cost. Castings provide an economical solution to achieving parts at or close to their designed dimensions. Our state of the art foundry division encompasses the following facilities.

Development

P.C.S has invested in facilities to achieve its goal of speedy product development of even the most complex castings.

  • Utilizing the best tools in the industry like MAGMASOFT, the development team evaluates the filling and solidification process of the Iron to ensure that castings are produced defect-free from the very first time.
  • Our Pattern Shop also ensures that all tooling is well maintained and serviced to ensure the quality of the castings throughout the life of the tool.
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Core Shop

Utilizing our expertise & facilities for making cores of different types, we are able to offer customers the perfect balance of intricacy and economy via utilization of the right type of core for each specific product through our extensive facilities:

  • Cold Box core shooters -
    Single Station Semi automated Cold Box Core Shooters of 5Kg Capacity -5 Nos
  • Shell core shooter – 1 No
  • Oil core making facility
  • CO2 core making facility

Moulding

SINTO FBO III High Pressure Moulding -
660 x 508 x 200/200mm @ 120 Moulds / Hour

DISA ARPA –
300 – 520 x 520 x 150/150mm
@ 60 Moulds / Hour

ARPA – 450 -
Box Size 1: 700/700/200+200 mm
Box Size 2: 600/700/200+250 mm
@30 Moulds/Hour

Any high-quality casting begins with a high-quality mould. This concept is clearly embodied in our investments in technology for producing moulds which result in castings with exceptional dimensional accuracy & superior surface finish.

The sand used in the moulds is a key ingredient in producing a high-quality mould. State of the art equipment such as Disa PS Polygonal Sieves, Sand Coolers from DISA and Intensive Sand Mixers from DISA are used for ensuring a high level of quality in the output sand.

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Melting

3 X 0.5 MT Inductotherm 1200 KW Tri-Trak

P.C.Sons has presently a melting capacity of over 40MT of Iron per day. P.C.Sons uses Medium Frequency Induction melting furnaces for optimal metal availability and power efficiency. The Company has installed multiple Inductotherm TRI TRAK furnaces which utilizes the latest technology in its power & control system to apply melting power to one furnace and holding power to another furnace, simultaneously to ensure close to 100% utilization during the melting process.

Fettling

P.C.Sons has presently a Fettling capacity of over 40MT of good castings per day. P.C.Sons uses high quality shot blast, Tumb blast machine ,Bench grinders and other fettling equipment's.

  • Hook Spin Shot blasting machine @ 500kg Capacity
  • Tumblasting Machine @ 500Kg Capacity
  • Pedestal Grinding Machines
  • Swing Grinder & Cut off Machines
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Testing & Quality Analysis

Quality is the hallmark of P.C.Sons Castings. Products undergo rigorous quality checks at every stage of production. In order to ensure the physical & dimensional properties of our products, our Quality Control Department has facilities for:

  • Spectrometer capable of all the 27 Iron based elements
  • Optical Microscopy equipment with photographic attachment and Image Analyzer.
  • Complete Sand testing facilities.
  • Hardness Testing Machine.
  • Tensile Testing Machine.
  • Instant carbon silicon analyzer
  • DFT Meter

We offer a wide range of internal capabilities for machining castings along with a very skilled group of machinists. We can tackle any casting the foundry can produce. We machine around 50% of the castings that we produce.

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Machining

  • CNC Horizontal Turning Centres - 12
  • CNC Vertical Turning Centres – 3
  • Conventional Lathe – 1
  • Conventional Drilling Machines – 2

Make : ACE MICROMATIC
Model : Jobber XL Elite
QTY : 2 No’s

8” GMT CHUCK

  • Max. Turning Diameter : 320 mm
  • Max. Turning Length : 400 mm

SPINDLE

  • Speed : 3500 rpm
  • A2- 5 Spindle

TURRET

  • Number of Tools : 8 No’s
  • OD Tool Size : 25 mm x 25 mm
  • Boring Bar Diameter : 40 mm
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Make : ACE MICROMATIC
Model : Jobber SJ 400
QTY : 2 No’s

8” GMT CHUCK

  • Max. Turning Diameter : 350 mm
  • Max. Turning Length : 400 mm

SPINDLE

  • Speed : 4000 rpm
  • A2- 6 Spindle

TURRET

  • Number of Tools : 8 No’s
  • OD Tool Size : 25 mm x 25 mm
  • Boring Bar Diameter : 40 mm

Make : LMW
Model : Lmw Lx20 Tl3
QTY : 6 No’s

8” SAMCHULLY CHUCK

  • Max. Turning Diameter : 320 mm
  • Max. Turning Length : 310 mm

SPINDLE

  • Speed : 4000 rpm
  • A2- 6 Spindle

TURRET

  • Number of Tools : 8 No’s
  • OD Tool Size : 25 mm x 25 mm
  • Boring Bar Diameter : 40 mm
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Make : Jyoti
Model : Jyoti Dx 250
QTY : 2 No’s

12” KITAGAWA CHUCK

  • Max. Turning Diameter : 480 mm
  • Max. Turning Length : 500 mm

SPINDLE

  • Speed : 3500 rpm
  • A2- 8 Spindle

TURRET

  • Number of Tools : 8 No’s
  • OD Tool Size : 25 mm x 25 mm
  • Boring Bar Diameter : 40 mm

Make : Jyoti
Model : JYOTI RX 20
QTY : 2 No’s

TABLE

  • Size : 800 mm x 530 mm
  • Allowable Load : 400 kg

TRAVEL

  • X Axis: 820 mm
  • Y Axis: 510 mm
  • Z Axis: 510 mm

SPINDLE

  • Speed: 8000 rpm

ATC

  • Tool Shank: BT40
  • Tool Transfer Time: 1.3 s
  • Tool Storage Capacity: 20 Nos.
  • Tool Max Weight : 7kg

4th AXIS –BTP80 TABLE

  • Ф 215
  • 8 Station Indexer
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Make : Ace Micromatic
Model : AMS MCV-400
QTY : 1 No’s

TABLE

  • Size : 800 mm x 530 mm
  • Allowable Load : 300 kg

TRAVEL

  • X Axis: 800 mm
  • Y Axis: 450 mm
  • Z Axis: 500 mm

SPINDLE

  • Speed: 6000 rpm

ATC

  • Tool Shank: BT40
  • Tool Transfer Time: 1.8 s
  • Tool Storage Capacity: 24 Nos.

4th AXIS –BTP80 TABLE

  • Ф 215
  • 24 Station Indexer

Testing and Quality Analysis

Quality is the hallmark of P.C.Sons Castings. Products undergo rigorous quality checks at every stage of production. In order to ensure the physical & dimensional properties of our products, our Quality Control Department has facilities for:

  • Coordinate Measuring Machine
  • 2D Height Master
  • Roughness Tester
  • Bore Dial & Air Gauges
  • Vernier Calipers & Micrometers
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CNC COORDINATE MEASURING MACHINES
ZEISS CONTURA G2 7/10/6 RDS

MEASURING RANGE

  • X = 700MM Y = 1000MM Z = 600MM

ACCURACY

  • EO = (1.8 + L/300)ΜM, PFTU = 1.8ΜM

RDS SENSOR PROBING

  • C-CAA indexing probe holder each articulating axis features +/-180°setting
  • Range with increments of 2.5°which corresponds to 20,736 individual positions

PROBES

  • ZEISS/ RENISHAW SENSORS TP6, TP20, TP200 (G2)
  • ZEISS SCANNING SENSOR VAST XXT TL3 (G2)
  • ZEISS MULTI POINT SENSOR XDT TL3 (G2)

LINEAR HEIGHT GAUGE (Optima Advantage Height Gauges)

Repeatability

  • On plane ≤ 0.0015mm (2σ)
  • On Bore ≤ 0.0030mm (2σ)

Measuring range

  • 0 -972mm (600mm)

Measuring accuracy

  • (2.5 + L / 250) μm
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