Innovation. Commitment. Trust
INDUSTRIESSG
The new age Investment Casting plant has a total installed Production capacity of 600 Metric Tons per annum. Spread over 14000 sq. m. this modern and efficient manufacturing facility is equipped with the latest CAD/ CAM design & simulation software, machineries from reputed International brands and comprehensive in-house testing facilities.
SGI has capabilities to produce precision Ferrous and Non-ferrous Investment castings
The Integrated Superior Metallurgical process followed at SGI comprises the latest proven methods along with engineered Shell System - Faster Drying, Fewer Dips, less shell cracking and improved casting surface finish. This enables design and manufacture of any type of parts from 0.01grams to 60kgs and 5mm to 400mm size.
SGI has the process capabilities to produce precision parts that require little or no machining work. Castings can be in either ferrous or non-ferrous materials including all grades of stainless steel, high and low carbon steel and bronze and aluminum.
SGI is proud to have some of the industry’s best and experienced talents to manage its manufacturing operations. Whether it is the Regulator body, spring case, closed & opened impellers, Valve Housings, Shafts, Disc Brackets or Holding Plate every effort is made to ensure appropriate design, superior raw material, appropriate process coupled with global quality standards. SGI guarantees total support with single source responsibility from design through finished product. Our team of qualified professionals ensure that your casting has the highest quality possible.
SGI Product engineering team is constantly involved in study of various metal and alloys and evolves new techniques to improve process of investment casting. Custom designed solutions are provided in partnership with customer development teams. SGI capable to RE-ENGINEERING the parts in Investment Casting process from Sand Casting, Forging and Other Several Metal Forming processes.
ABOUT US........................................................................................
CAPABILITIESNORMAL LINEAR TOLERANCES - ISO 8062 | DCTG 6 | VDG - P 690 D2
DIMENSIONAL
Flatness & Straightness Flatness and straightness can be achieved 0.03 to 0.05 TIR per linear inch.
ConcentricityConcentricity can be achieved not more than 0.005 times the difference between the diameters in inches.
Radii & Fillets0.03” maximum corner Radius and 0.06” minimum fillet are recommended.
Wall Thickness:Minimum wall thickness is 2 mm.
Angular ToleranceAngular Tolerance of ± 1° is normal.
Machining Allowance0.5mm to 2.0mm wherever machining fitment is expected
Letter/Logo/NumbersRaised letter with maximum of 0.020”projection
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Ferrous & Non Ferrous Castings
0.01Kgs to 60Kgs Casting Weight
5mm to 400mm Casting Size
VDG P690 D2 All dimensions are in mm
Nominal Dimension Tolerance Zone
0 ≤6 0.16>6 ≤10 0.2>10 ≤14 0.24>14 ≤18 0.28>18 ≤24 0.34>24 ≤30 0.4>30 ≤40 0.5>40 ≤50 0.6>50 ≤65 0.76>65 ≤80 0.92>80 ≤100 1.06>100 ≤120 1.2
ISO 8062 DCTG - 06 All dimensions are in mm
Nominal Dimension Tolerance Zone
0 ≤10 0.16>10 ≤16 0.2>16 ≤25 0.24>25 ≤40 0.28>40 ≤63 0.34>63 ≤100 0.4>100 ≤160 0.5>160 ≤250 0.6>250 ≤400 0.76>400 ≤630 0.92>630 ≤1000 1.06>1000 ≤1600 1.2
ALLIED FACILITIES Rapid Prototying using 3D Printing/SRM/Flask Method/ Vacum Pouring Facilities to develop parts in shorter lead time.
Machining Facilities - CNC Turing/Milling & Gear Hobbing
Assembly and Fabrication Units to deliver customer special requirements.
Special finish - Painting/Powder Coating/Electro Plating and Electro Polishing.
CASEHARDENING STEEL
C10
16MnCr5
C15
18CrMo4
12NiCr3
18NiCrMo5
16CrNi4
18NiCrMo7
16NiCr11
20MnCr5
16NiCrMo2
20CrNi4
16NiCrMo12
20NiCrMo2
TEMPERING STEEL
C20
C50
32CrMo12
39NiCrMo3
C25
C60
34NiCrMo16
42CrMo4
C30
25CrMo4
34Cr4
40NiCrMo2
C35
C28Mn
35CrMo4
40NiCrMo7
C40
30CrMo4
35NiCrMo15
41Cr4
C45
30NiCrMo8
36CrMn5
50CrMo4
C55
30NiCrMo12
38Cr2
90Mn4
STAINLESS STEEL
AUSTENITIC (AISI)
201
304H
316L
317
202
304L
316H
317L
301
305
316LN
317LN
302
309
316N
321
303
310
316F
347
304
314
316Ti
304LN
316
316Cb
DUPLEX (UNS)
S32900 S31803 S32304 S32550 S32760
FERRITIC (AISI)
405 409 410S 430 430F 434 439
446
MARTENSITIC (AISI)
403 414 416 420 420F 422 431
440A 440B 440C
AUSTENITIC GRAY IRON - Ni Resist
NON FERROUS – ALL COPPER BASED ALLOYS
• SGI utilizes a system of tooling standards to ensure uniform high quality design and fabrication of wax injection dies which are guaranteed for the life of the part.
• Type of tooling:ManualPrototype or low volume production work.
AutomaticHigh volume, Parts that are too large or fragile for manual operation
• Configurations that do not allow metal cores in tooling to be drawn due to undercuts or complicated internal shapes must be treated in one of the following ways:
Collapsible Cores - Lowest piece price..
Loose Inserts - Best for low volume parts
Multi-Piece Wax Assemblies - Best for certain configurations, with wide tolerance
Soluble Cores & Pre-Formed Ceramic Cores - Provides excellent flexibility during shell building process at a moderate additional cost..
TOOLING
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CASTABLE ALLOYS AT SGI INDUSTRIES
• Equipped with precision CNC Machining Centers and CNC Gear Hobbing machines
• Machining QMS process certified with ISO/TS 16949:2009
• Capable and Stable process through Cp & Cpk studies
• Availability / Performance / Quality improves through OEE studies
• Machining of Parts from Forged Parts, Bar Rods, Investment Castings, Sand Castings, Pressure Die Castings, Gravity Die Castings.
MACHINING CAPABILITIES
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MACHINE TYPE / DETAILS TURNING MILLING GEAR HOBBING
Machine Stroke Length in mm
X 125 - 250 510 - 762 30 - 750
Z 195 - 1000 510 1000 Max
Y NA 510 250 Max
Options NA C Axis NA
Chuck Size in mm 165 - 400 NA NA
Gear Module NA NA 1 - 10
Number of Tool Stations 8 21 1
Number of Machines 20 5 7
MANUFACTURING FACILITY
• Solid Works and Master CAM for Mold Design and Machining Process
• Dual Injection Type PLC controlled Wax Injection Press.
• Soluable Core to form Intricate shape in single pattern.
• Imported Refractories and Binders shell system to meet Premium Quality
• Combination Mixing Procedure with High Shear Mixture and Jar Mill to obtain homogeneity of slurry.
• Auto Ambient Control Shell Drying Room with Special air feed provision to ensure optimum and uniform drying of shells.
• PLC controlled shell Sintering furnace.
• IGBT Induction Furnace with Argon Diffuser Setup.
• 1 Ton Auto Controlled Water Quenching Furnace with digital recorder.
• 1 Ton Auto Controlled Tempering furnace. (Normalizing & Annealing)
• Power Backup - 250KVA Diesel Generator.
• High Precision CNC TURING, MILLING AND CNC GEAR HOBBING Facility.
• Assembly and Fabrication Facilities - Allied unit
• Painting/Powder Coating/ Electro Plating/ Electro Polishing- Allied unit.
• RAPID PROTOTYPING (3D Printing/SRM/ Flask Technology/Vaccum Pouring).
• RE-ENGINEERING the parts in Investment Casting process from Sand Casting, Forging and Other Several Metal Forming processes.
QUALITY ASSURANCE
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INSPECTION
INSPECTION AND TESTING FACILITY
• Each tool is CMM inspected prior to issue onto injection floor ensuring compliance with customer’s specifications.
• We provide first piece wax inspection as well as final inspections to ensure that all pieces are conforming to the customer’s specifications.
• 100% Visual Inspection
• Dimensional inspection as per agreement made with customer
• Physical and chemical testing at various stages:
• Spectrographic analysis
• Wax Property analysis.
• Slurry quality analysis
• Mechanical properties like Tensile strength, Yield Strength, Elongation percentage, Reduction area, Hardness and Impact Testing
• Corrosion resistance Testing
• Radiographic, ultrasonic, and Magnetic Particle inspection are performed at local professional laboratories to ensure the soundness of quality.
• Process Control of Waxes and Slurries
• 2D/3D measuring device used for layout inspection.
• Ferrous & Non Ferrous Based Optical Emission Spectrometer – Brucker Q4 Tasman with Nitrogen - 35 Chemical elements can be measured
• Computerized Universal Testing Machine – 40T
• Optical Brinel Hardness Tester – 3000Kgf
• Rockwell Hardness Tester
• Izod/Charpy Impact Tester – IS & BS
• Process Material Analytical Lab
» Shell - Hot Air oven/Centrifuge/pH meter
» Wax - Muffle furnace
• Pressure Testing - Hydro & Pneumatic
• Surface Plate, Angle Plate and Between Center.
• Measuring instruments like Digital Height Gauge, Calipers, Micro meters, etc..
• Roughness Tester
• 3D Coordinate Measuring Machine
• Vision Inspection System
ISO 9001 - Quality Management System
ISO 14001 - Environmental Management System
OHSAS 18001 - Occupational Health and Safety assessment series
Casting Unit
Machining Unit
SYSTEMS
Pressure Equipment Directive.
ISO 9001 : 2008 - Quality Management System ISO/TS 16949 : 2009
• Automobile
• Agriculture
• Air Conditioning & Refrigeration
• Boiler Mountings & Accessories
• Defense
• Compressors Parts
• Crimping Tool Industries
• Cooling tower & chilling plants
• Diesel & Gas Turbine Equipments
• Dairy Equipments
• Electrical engineering Industries
• Earth Moving machinery
• Food Processing Machinery
• Hydraulic Products &Equipments
• Industrial machinery parts
• Marine Equipments
• Mining Equipments
• Industrial Pumps & pumping Equipments
• Textile
INDUSTRIES SERVEDDue to the advanced manufacturing process adopted at SGI, we are capable to manufacturing a comprehensive range of metal alloy castings. With our proficiency in this domain experienced team and Advanced Infrastructure, we can meet the diverse requirements of a wide variety of industries including
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Pondicherry
Bangalore
Hyderabad
Mumbai
Delhi
A
B
Chennai
Regd. OfficeNo. 104, S.V. Patel Road, Pondicherry-605 001, INDIA.Email : [email protected]
Machining DivisionR.S. No.74/2B, Madukarai Main Road, Mangalam Pondicherry-605 110, INDIA. Phone: +91 413 2660733 I www.supremeautomech.comMobile: +91 9994458091 | [email protected]
Investment Casting Division12/1A, Villianur Main Road, Uruvaiyar, Mangalam Post,Pondicherry-605110. INDIAPhone : +91 413 2970422 I www.sgalloys.comMobile : +91 9655249619 | Email : [email protected]
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SGI Industries located South of Chennai
• 150Kms from Chennai Airport
• 14Kms from Pondicherry Airport
• Robotics and Conveyorised Shell Room
• ISO 27001:2013 - Information Security Management System certification and
• Metallurgical Laboratory
LOCATION MAP
GOING FORWARD...
INDUSTRIESSG