Casting the Quality Spell

A bike ride gives a sense of freedom and adventure, and is the favourite vehicle for the free souls. The clan of bike enthusiasts swoon at the sight of a high range bike. But, for the common man, motorbikes are simply a combination of convenience and adventure. 

In India, you will see people across all age groups riding bikes. Honda has launched The Dream Yuga, positioned as a bike for masses. It looks like another best seller from Honda. How does Honda come up with such excellent automobiles? The components that go into the manufacturing of a bike like die casting components, the braking and the suspension systems etc. make it sturdy, and give us a safe ride.

The Endurance Group serves the automobile industry and contributes in making two-wheelers attractive and reliable. Honda Motorcycle & Scooter India Pvt. Ltd. is one of our clients, and trusts us for the quality of two-wheeler components we manufacture. We manufacture aluminium casting, transmission, braking, and suspension components for automobiles. 

We manufacture aluminium die casting components, which are intricately shaped. We have Machining, Assembly, Painting, Tool Room, Gravity Die Casting, etc. all under one roof. In India, we have manufacturing facilities at Aurangabad and Pune in Maharashtra, Manesar in Haryana, Pantnagar in Uttaranchal, and Chennai in Tamil Nadu. We have manufacturing facilities at Italy and Germany too. 

The focus areas at Endurance Group are as follows:

Organic and Inorganic Growth:

We aim at expanding our business by increasing our customer base and output, acquiring new sales and through mergers and acquisitions.

People:

The success of our company depends completely on the calibre and capability of our people. They are our assets and we believe in upgrading their skills and talent.

PQCDSM:

The pillar on which our business stands is Productivity, Quality, Cost, Delivery, Safety, and Morale. The main area of focus will always be quality.

QCD:

While searching for the best vendors we consider Quality, Cost and Delivery. Having the best vendors will support Endurance in a competitive environment.

R&D:

A strong in-house resource and development centre will always be our forte. Strong foreign collaboration will lead to spreading our reach and improving our quality standards.

With 19 plants across India, Italy and Germany, we manufacture die casting components including alloy wheels, and other components for our clients like Tata Motors Ltd., Mahindra & Mahindra Ltd., Audi AG, Nissan Motor India Pvt. Ltd., etc. The trust that our clients have on our products, motivates us constantly to keep raising the bar of quality.

Die Casting Process - History and Advantages

Aluminium die casting came into being in the 18^th Century. It was originally created to produce movable parts for the printing industry. An automated type casting device called the Linotype machine was created by a man named Otto Mergenthaler in 1885. This became popular equipment used in the printing and publishing industry. Die casting led to the creation of other designs and applications used to create products of different kinds to ease the growth and demand of consumer goods. This gave way to the mass production of aluminium goods. The year 1892 saw the mass production of phonographs and cash registers. These parts were mainly made out of tin and lead. 

 

Developments and newer applications gave way to using metals like aluminium, zinc, magnesium and copper. Today, one can find a number of aluminium die casting companies the die casting process can be used to accommodate products of various shapes and sizes. 

 

Aluminium die casting are made by injecting molten metal with considerable force into a steel mould called a die. The sizes of the die casting machines can be anywhere between 400 and 4000 tonnes. There are two methods used to inject the molten metal. The methods are the hot and cold chambers. Hot chamber machines are also known as goosenecks. A pool of molten metal is used fill the gooseneck and then the metal is injected into the die using a hydraulic piston. 

 

Cold Chambers are used when it comes to die casting metals like aluminium, magnesium, zinc and copper. Then a certain amount of molten metal is poured into a cold chamber and is injected into the die. This process is slower than the hot chamber process.

There are reasons why aluminium is preferred than other metals when it comes to the process of die casting.

• It is lightweight, and at the same time has the appropriate amount of weight and stability
• It has good resistance against corrosion
• It has thermal and electrical conductivity
• It can maintain its strength even at high temperatures

There are many reasons why aluminium die casting products and companies are popular.

Fast production: Die casting provides complex shapes with dimensional accuracy and stability. Little or no machining is required to create dozens of identical castings. The products are durable, resistant to heat and long lasting.

Strength and weight: Plastic moulded products do not have the same weight and strength that die cast parts do. Thin wall castings made from aluminium are stronger and lighter than those possible with other casting methods. 

 

Easy Surface preparation: Die cast parts are plated quite easily and they require minimum surface preparation. They can also be produced with smooth or textured surfaces.

Aluminium die casting companies have to follow strict quality control procedures to make sure their products reach popular standards of excellence. Thanks to these reasons, companies can make more than 500 million in producing and selling aluminium products.

Aluminium Die Casting Process

Die casting is a process where molten metal is put into a mould cavity using considerable pressure. The die casting method is a low cost and high product generating method. It is mainly used for producing small or medium sized parts. 

 

Die casting is used in a variety of industries including the industrial, consumer and commercial industries, which require using different kinds of metals for different products. Die castings are usually made of metal alloys like zinc, copper, aluminium, tin and lead. Companies that specialize in die casted parts use various methods to manufacture the components. 

 

The major ones are gravity die casting, high pressure aluminium casting and low pressure aluminium casting. Alloy wheels are made using the low pressure aluminium casting process. Aluminium die casting is one of the more popular methods. 

 

Aluminium is a popular metal alloy used. The reason behind this is that aluminium is a light weight metal, but also has an ability to remain stable when moulding it into complex shapes. It retains its strength at high temperatures. It has a very good resistance to corrosion. Aluminium is known its good mechanical properties and its high electrical conductivity. 

 

The automotive industry is one of the biggest industries to use parts that have been manufactured using the aluminium die casting process. Many automotive companies have replaced steel with aluminium for the car’s frame and automotive components. The reason for this is that aluminium is lighter than steel, making the car leaner and faster. Lighter cars mean less consumption of fuel. It is easier to mould it into complex parts. Also, the labour cost for aluminium is less. 

 

With a high demand for aluminium parts, many aluminium companies have come up that cater to the industries, manufacturing aluminium die casted parts. The die casting process also allows the manufacturers to produce the product according to the client’s specifications. The products can be light weight, ranging from a few 100 gms to a few kgs, depending on the requirement.

One of the newer processes that have been introduced in die casting is the pressure injection process. A number of methods are being used to automate the die casting process. This helps to continuously provide quality control. Automated systems are used to ladle metal into chambers, lubricate dies. Microprocessors adjust pressure and velocity to create the product according to the specification provided. Thus, it is simple to produce a component of according to one’s needs.

 

The work of aluminiumdie casting manufacturers is majorly influenced by the research and development that goes into creating better systems to improve the production process. R&D usually comprises a highly qualified team that handles a large amount of imported and indigenous equipment. Automotive components manufacturers use the aluminium die casting process so that the component will have a long life. They can be designed to add to the visual appeal of the vehicle. That is why many automotive designers ask for parts that can be produced using the aluminium die casting method. 

Learn More-  Alloy wheel manufacturer

Advantages And Importance Of Alloy Wheel

This blog discusses alloy wheels, how it has become a popular option for wheel manufacturers and a favourite of customers. It has also become a must have customers from different vehicle genres.

The alloy wheel, once considered a poor option for motorsports, has become a world favourite for anyone who loves anything to do with motor vehicles. During the 1960s and 70, alloy wheels or ‘mags’ (derived from the fact that they were made from aluminium and magnesium) were not considered safe for common vehicles. This was due to the fact that aluminium, though light in weight is brittle, and technology hadn’t improved to give it strength as well as keeping it lightweight.

As technology and motorsports began to grow in size and popularity, new ways to produce aluminium were developed, making the metal stronger and at the same time maintaining its weight. Most alloy wheels are cast and few brands are forged. The ability to mould the metal and creating beautiful designs for tyres has made the wheels an important component for luxury or sport vehicles. Many companies even offer alloy wheels exclusively for some of their products.

Today, aluminium is a hot favourite for people who manufacture motor vehicles and motorsports enthusiasts. Many feel that having a larger alloy wheel is better not only for the bike but also for the atmosphere. But test by various auto magazines have indicated that having large alloy wheels reduce the fuel economy of a vehicle. It also affects the riding comfort and noise from the tyres. 

Many companies that produce super cars and sport cars are known for their love of alloy wheels. This is a trend that is seen in many countries around the world, including America, Italy, Britain, and of course, Germany. 

But that hasn’t removed the allure of the wheels from the eyes of customers. It is still considered a favourite by enthusiasts. And India is certainly no different. One of the main cities where motor vehicles are manufactured in India is Pune. The city, which in recent years has been dubbed ‘Detroit of India’, has become a haven for auto manufacturing companies. Many alloy wheel manufacturers and distributors have also come up here. Wheels other products are cast using intricately shaped castings and they weigh between 400 gms to 8.5 kgs per piece. Manufacturers make sure to do most the work in-house, from high pressure; low pressure and gravity die casting, to machining, painting and finally assembly. Only a few products like Clutch Housing, Converter Chamber, Cylinder Head Cover, Front Wheel Hubs are sent for overseas casting.

Learn More - Aluminium Die Casting Manufacturer

Shock Absorbers - For a comfortable journey

This blog discusses shock absorbers. It comprises the different types of shock absorbers and its uses. It also talks about the various components with which it is made.

Shock absorbers may not be considered a vital part of an automotive, but actually, it is one of the crucial parts that help to provide a smooth and comfortable ride for the customer. Shock absorbers are not exclusive to automobiles and are used in a variety of machines like airplanes and industrial machines. They also come in various shapes and sizes. A shock absorber is also called a dashpot. Sometimes, they simply called shocks.

There are many types of shock absorbers, which are commonly used by the public. The most well-known are pneumatic and hydraulic. Pneumatic shock absorbers use air to help dissipate the energy caused by sudden and vibrations and oscillations. The other type is hydraulic shock absorbers; this uses liquid to help dampen energy in spring oscillations. There are also spring based shock absorbers that are commonly found in automobiles. Many may not know this type of but shock absorbers are also used in buildings and bridges to reduce the seismic activity caused by an earthquake.

While the above shocks are common knowledge, there are other types that are used for various purposes.

• Friction disks: These are used in automobiles contain a disk made out of leather. The disks can be loosened or tightened by a simple screw.
• Lever arms: These are also used in automotives and contain internal valves that can be changed to suit particular situations. These help the driver or rider to control the car with ease.
• Magnetic dampers: These change the viscosity of the fluid using electromagnets. This kind of shock is also found in prosthetic limbs.

Today, you will find shocks being produced in India that comprise a variety of elements. Many of them are equipped with a piston rod for a better outcome. Many shock absorber manufacturers import the valves that are used in hydraulic shocks. The shocks are tested completely by computers to make sure that they are at full potential. Metal oil seals are also used to provide a longer lasting product. Suspension springs and dampers are usually made together as both components are important together for the concerned machine, automotive or structure.

Learn More: Aluminium Die Casting Manufacturer

Mold Strong And Smooth With Die Casting

What is die casting? Answer: It is a process which produces engineered metal parts by forcing molten metal under high pressure into steel molds. These molds, called dies, can be sharply made, with smooth surfaces, and are suitable for a wide range of serviceable and attractive finishes.

The process of die casting is not cheap. Therefore, the products need to be of high volume and be mass-produced. Such products can be found in lots of commercial, consumer and industrial devices. They may range from automobiles to toys. The components may be as complex as a connector housing or as simple as a sink faucet.

The earliest products of die casting by pressure injection occurred in the mid-1800s, with a patent being given to Sturges in 1849. This machine was manually operated. The process was limited to printer’s type only. Later, the development of other shapes began to increase. Also, parts for phonographs and cash registers began to be mass produced.

The earliest die casting metals were Tin and Lead. Their use began to dip with the introduction of Aluminum and Zinc. Copper and Magnesium alloys followed quickly.

The casting process has today changed. From low-pressure injection methods it is now high-pressure casting, with pressures up-to 4,500 pounds per square inch. High integrity, near net-shape castings with superb surface finishes can now be produced. 

The die casting method is expanding and its applications are spreading to almost every recognized market. Now, products can be made in a variety of shapes, sizes with wall thicknesses that are durable and strong.

Products made from die casting have a long service life and can be made to complement the visual appeal of the neighboring parts. 

One great advantage of die casting is that it produces components at high speeds. These are dimensionally stable and durable, and are also heat resistant.

Die cast parts are more powerful than plastic moldings of the same dimensions. They are stronger and lighter than those from other casting methods. 

The two notable advantages of die casting are: 

 

1. Superb dimensional precision (dependent on casting material, but typically 0.1mm for the first 2.5cm (0.005inch for the first inch) and 0.02mm for each additional centimeter (0.002inch for each additional inch).

2. Smooth cast surfaces (Ra 1–2.5 micrometers or 0.04–0.10 thou rms).

Several metal alloys such as Aluminum, Magnesium, Zinc, Copper, Lead and Tin are available for die casting. Each of these offer particular advantages. The Aluminum alloy is light, while having high dimensional stability for difficult shapes and thin walls. It has good corrosion resistance, and high thermal and electrical conductivity. This alloy is strong even at high temperatures.

Aluminum Die Casting Products are present in LCD TVs, cash registers, screen monitors, automobiles, communication base equipment, heat sinks, bicycle brakes, telecommunication equipment, lotto machine monitor screens, printers, etc. 

All Aluminum Die Casting Products designed at ENDURANCE are tested rigorously. The quality is never compromised. ENDURANCE wants to set a quality benchmark in the industry and wants to manufacture high quality products that eventually merge its goal to focus on a profitable and sustainable growth structure.

Learn More: Aluminium Die Casting Manufacturer

Tips For Aluminium Die Casting

Aluminum die casting is a manufacturing process in which molten aluminum metal is injected, under pressure, into a hardened steel die or also called mold. Aluminum can be cast by any process of metal casting. It is melting point is low compared to other metals and you can choose to cast aluminum at home. It can be done by die casting, permanent mold casting, sand casting, plaster casting, investment casting or continuous casting. Whichever process you choose, you have to follow a certain order and pay extra attention on safety issues.

If your objective is to liquefy and thrown steel, you need a foundry to do it. To develop it, use available products that you will see in a industry or specialized shop. You will execute only easy steel launching, so you do not need a professional foundry. You can even develop it of old trash. Make the foundry by burrowing an opening in your garden, making a shoot and using billows to fan it. Use a thermostatically managed electrical warm with electrical coordinator and gantry for going the crucible.

Make the mold

To result in the form, first you have to generate a design. When it is prepared, you have to choose which strategy to use in developing the form. You can do it often, but using memory space-age foam or wax are the most typical methods. You can choose to click the design you created into a box which is packed with natural sand. When you eliminate it, you will have the mark. Next you need to add the form content in this mark and put it in a heater.

Melt the Aluminum

In obtain to liquefy the steel, you need the crucible and a heater. When you put the crucible in the heater, it will gather the dissolved aluminum, which will be added into the style. Make your own crucible, but it has to be of a content that can fight incredibly hot conditions. There are also retail created crucibles that you can buy. They are usually created of graphite or plastic carbide.

Safety Measurements

There are certain resources that allow the crucible to be properly put from the heater and dissolved steel to be added into the form. These resources change from crucible to crucible. Crucibles are not used to last for a long time, so secure yourself while reducing steel. Protection mitts, footwear and bluejeans are necessary if you are organizing to thrown steel. Never touching a operating crucible even if you are dressed in heat-resistant mitts.

Endurance is one of the best alluminium die casting company to manufacture aluminium die casting products for automotive market using new technology and models. Our products provides following benefits -

• Cost saving

• Long life

• Less wear of the chamber

• Breaking down of the exchanging time.

Learn More -  Aluminium Die Casting Manufacturer