Shell Core, Shell Mould Casting Manufacturer

Gray Iron, Ductile Iron & SIMO Grade Quality Casting by Shell Core and Shell Mould Route

Capacity:- 700 T/month

Ratna Udyog’s foundry Division is an IATF 16949:2016 and ISO 9001:2015 certified company. We manufacture medium to high volume, small to medium sized Castings in Grey Iron and S G Iron. Our team, infrastructure & processes are capable of producing intricate Grey Iron and Ductile Iron Castings with high precision. For meeting the challenges, Ratna Udyog Team uses its ability of fast development, its flexible manufacturing approach and supporting infrastructure. Ratna Udyog has in-house machining facility which is again designed to cater to a variety of weight, size and volume requirements.

We use Shell Moulding Process to ensure high dimensional accuracy, excellent surface finish and clean internal passages in all our products. We are equipped with modern facilities like core shooters, Induction Melting, Spectrometer, Internal shot blasting, Mechanical testing equipment, casting inspection facilities like Endoscopy, Microstructure testing, hardness testing and CMM for machined component inspection. We also have reliable local tie-ups for services like Honning, Casting coating, Heat treatment etc.

Our Shell Moulding Foundry Capability

CASTING MATERIAL

Gray Iron Grades :
FG-160, FG-200, FG-260, FG-300

Ductile Iron Grades :
400/10, 450/12, 500/7, 600/3 & 700/3

All SIMO Grades

Vermicular Castings

CASTING RANGE

Weight : 0.5 Kg to 50 Kg

Size : Maximum 600mm X 400mm x 400 mm

ANNUAL VOLUME

8400 Metric Ton / Year

VALUE ADDTION

  • Machining
  • Phosphating
  • Coating
  • Painting
  • Plating
  • Leakage Testing
  • Heat Treatment

Segments We Serve

Automotive
Automotive
Hydraulic
Hydraulic
Transmission
Transmission
Process Automation
Process Automation
Pump Manufacturer
Pump Manufacturer
Electric Motor Manufacturer
Electric Motor Manufacturer

Our Shell Core, Shell Moulding Foundry Infrastructure

Methoding

We use Simulation Software (Virtual pouring) which predicts the complete casting process including filling, solidification, cooling and allows the qualitative prediction of various properties of the cast product. We use this facility for methoding which saves actual shop trials and saves time in producing good castings at first go. The necessary method cards are made for every item and are preserved.

Radiography tests are carried out from reputed out source as per customers’ demand.
Methoding
Moulding

Moulding

We use Alpha set No-bake process for Moulding and have ‘SPAN ‘make line of Core Shooters with maximum core size 600 mm x 400mmx 400mm.

Melting

At the melting section, we have Inductotherm make Induction Furnace 500 kg Tri Track facility and also a 300 kg additional furnace. The melting section has online Carbon Silicon Analyzer and molten temperature measurement facility. On line display system with colour coding, is directly connected to the Lab Spectrometer for the fast transfer of data and ease of the operators.

Melting
Pouring System

Pouring System

  • Car track with 30 Pallets for pouring of shell moulds
  • Pouring ladle movement with the help of monorail
  • Up & Down movement of the ladles is carried with help of wire rope Crane

We have Various ladles from 150kg to 300Kg with Lip & bottom pouring arrangement.

  • Magnesium Treatment Ladle having 300 kg capacity with Tundish cover
  • Geared Pouring ladles having capacity of 150 kg capacity

QC, Testing & Inspection Facilities

We strive to exceed the quality requirements of our esteemed customers. This is possible because of our strict in-process controls at all levels.

Resin Sand Testing Equipment
  • Sieve Shaker with sieve set
  • Peel Back Tester Digital
  • Transverse Strength machine
  • Hot Shell Tensile tester.


Chemical Composition Checking Facility

‘Shimatzu’ make Optical Emission Spectrometer PMT Based: Model PDA 5000 and online Display board.



Metallurgical Sample Preparation Facility

‘Chennai Metco ‘make sample preparation machines namely.

  • High Speed Spectro Grinder
  • Abrasive Cutting machine
  • Hydraulic Specimen Mounting Press
  • Floor model four-disc Grinder/Polisher


Microstructure Checking Facility

‘Metalsoft’ make Microscope with Image Analysis with Prometal 8.8.6 model MV 625 H



Hardness Checking Facility

‘Fine ‘make Hardness checking machine consist of Brinell and Rockwell hardness

  • Core Gas determinate
High Speed Spectro Grinder

High Speed Spectro Grinder

Abrasive Cutting machine

Abrasive Cutting machine

Hydraulic Specimen Mounting Pres

Hydraulic Specimen Mounting Pres

Floor model four-disc Grinder/Polisher

Floor model four-disc Grinder/Polisher

Optical Emission Spectrometer

Optical Emission Spectrometer

Hradness Checking

Hradness Checking

Quality Policy

We at Ratna Udyog, are committed for customer satisfaction through supply of quality finished products, at right price in desired time, with active involvement of employees at all levels through continual improvement & training

Our Global Reach

It is the solution-based approach that has helped us get wide reach across the globe leading us to export more than 40% Export of our products to USA & Europe.

U.S.A
Europe

Our Customers are Most Treasured Assets

Our long-time customers who have appreciated our overall excellence of conducting business are

Cummins
Poclain Hydraulics
Tata Motors
Faurecia
ABB
Eaton
Carraro
Mahindra
Siemens
DANA USA
Bosch
DANA USA