Our Achivements
WHY AAKAR
Many of you have an impression about the Aakar firm, that we manufacture dies and casting according to your needs. Its indeed true, but we have been also redeveloping the moulds, dies for various big firms including Mahindra itself. As we have been in this field for several years. We have clearly understood the needs of our customers. The basic principle of our firm and the experience had encouraged us to lay our imagination and creativity at a larger scale. This special attributes makes us unique.
Some Of Our Facscinating Projects
- Inner Casting
- Jawa Engine and Vehicle part
- Mahindra & Mahindra transmission housings
- Crank Case & Hubs
Inner Casting Mahindra Electric
Application of the part
This part is basically used in the transmission system in electric vehicle.
This was the most interesting project for Aakar. The die was to be made with Variable thickness throughout the die. The difficult part was the core.
Marked zones were very difficult to die cast. Shrinkage porosity was the major concern due to the product design. Many experts had forecasted for porosity level 4-5. which was achieved up to level 2-3 by us.
Crucial Actions:
- Optimizing product design
- Latest technologies used
- Use of squeeze pin arrangement
1). Optimizing Product Design
some changes were suggested to improve metal flow & solidification of the part during die casting.
A). For better metal flow its thickness was increased connecting the critical zone.
B). Extra ribs were added to ensure better metal flow through the die at critical zone.
C). Weight reduction pockets suggested to improve solidification at thick areas.
D). Squeeze pin arrangement was planned to minimise the porosity at the critical zones. i.e. we have to squeeze the semisolid metal at specified area by means of hydraulic cylinder. The areas were decided at opposite side of the zones & necessary changes were done in the parts.
2). Latest technologies used:
We have used latest available technology for producing defect free casting:
- Provision for vacuum
- Jet cooling used at critical areas where conventional cooling becomes in effective.
3). Use of squeeze pin arrangement.
The challenge was placing the hydraulic cylinder due to
- Two squeeze points were close to each other. So two separate cylinders could not be fitted in the limited space. We have to design & manufacture special cylinder with two bores which we accomodated in the space.
- Due to ejector pins space was even more concern for this arrangement.
- One Of The Most Renowned Motorcycle Of India In The Following Few Years.
- We feel extremely happy to share our foremost work with JAWA R & D.
- Most of the vehicle builds including the Engine Dies were manufactured by our firm.
- The number of moulds manufactured by us tallies up to 16 dies. It was a pleasure working with JAWA R&D. We had a great communication with them which helped us to convey our creativity in building a fantastic vehicle.
- The best accomplishment to us was that we cleared almost all dies trial in the very first attempt and the vehicle build was completed with the same parts.
Total 16 no parts die manufactured
- Cylinder Block
- Clutch Cover RH
- Side Cover RH
- Cover Magneto LH
- Cover Rear Half LH
- Cover Cylinder Head
- Rear Wheel Hub
- Front Wheel Hub
- Crush Drive Housing
- FF Upper Cowl
- FF Lower Cowl
- Rear Brake Panel
- Holder Lower
- Counter Weight
Some of the JAWA casting developed
Crank Case
- Its one of our recent project with Classic Legends.
- Crank Case:- This time it was a bit different as we had faced difficulty in the oil passage pipe. We also gave our opinion about fitting development of pipe. also the crank cases are always a bit critical to develop due to its application & porosity requirements. The most fascinating thing was that we have achieved defect free casting in first trials.
Front & Rear Brake Drum
Learning from our mistakes we had developed a unique gate through Three plate mould method to minimize the shrinkage porosity & non filling issue And we successfully minimize to the least that is to level 2.
This concept was first time introduced & implemented successfully.
Some advantages over conventional method :
- Improved yield
- Easy for gate cutting
- Reduced porosity
- Non filling reduced.
Mahindra & Mahindra transmission housings
- Another venture with Mahindra & Mahindra
- This time we had manufactured some Heavy Dies for Mahindra.
- The castings were big which require big capacity pressure die casting machine such as 2000-2200 tonnes.
- Latest technologies were incorporated to minimise the casting defects
- squeeze pin arrangement
- jet cooling
- vacuum arrangement
The Dies Manufactured by us are:-
Conclusion
- After Having A Look About These Projects The Incentives About Aakar Must Have Been Clear. That At Aakar We Just Don’t Only Do Hardwork But We Also Indulge In Appropriate Smart Work.
- Our Unique Recommendation Are Taken By Our Expertise Design Team To The Betterment To Your Firm.
- Its Always Our Pleasure To Try Out Challenging Project.
- Sometimes The Dies Are Way To Complicated There Are Issues Related To Shrinkage Porosity , Fillings Etc. Instead Of All The Hurdles We Keep On Improving And Work Until We Succeed.
- We As A Complete Unit Are Effective At Troubleshooting. We Usually Understand The Complication And Find Out Effective Means To Solve The Problem, So That Our Customers Are Tension Free, Even Our Recommendation Are Appreciated By The R & D Department Of Firms.