The solidification process in casting is highly complex; therefore, industries often use simulations to study it before actual production. As molten metal cools and solidifies, it undergoes transformations that may lead to defects.

SGK’s best-in-class in-house 3D models and simulation software applications help us minimize defects and process-related issues in the complex casting process.

Moulding is a manufacturing process in which molten metal is cast into the final shape of a product. At SGK, silica sand is used as the moulding material. The moulds are handled through a loop system, allowing continuous movement and improving overall productivity

We follow the Alfa Set No-Bake system for the mixing of resin and catalyst using an Omega make mixer with a capacity of 10 MT/hour, which is automatically controlled through a PLC system.

Melting is the first major step in the casting process, during which solid metal is heated until it becomes liquid. This process typically takes place in a separate melting area within the foundry, using furnaces powered by gas or electricity, depending on the type of metal and the production setup.

Once the metal reaches the required temperature and composition, it is carefully transferred to the pouring area, where the moulds are prepared and assembled for pouring.

SGK houses a melting facility equipped with a 1,000 kg/600 kW induction melting furnace with two crucibles and a 500 kg/350 kW induction melting furnace. The facility has a production capacity of 300 MT of castings per month.

Heat treatment is the process of heating and cooling steel to improve its physical and mechanical properties. It enhances the strength and durability of the steel for its intended application

SGK’s heat treatment setup includes four furnaces with capacities of 3 metric tonnes and 5 metric tonnes, respectively. SGK also has a water quenching facility with an effective agitation system to ensure proper and uniform cooling.

All our furnaces are calibrated in accordance with API 6A standards by an NABL-accredited third party. To maintain accuracy and consistency, thermal surveys are conducted annually, and thermocouples are calibrated every three months.

SGK’s machining facility hosts a full range of CNC, VMC, and HMC machines. These machining systems help us achieve high accuracy, improved consistency, reduced setup time, better surface finish, and enhanced productivity.

CNC lathes are computer-controlled machines used to shape metal by rotating the workpiece while a cutting tool removes material. These machines are primarily used for manufacturing hydraulic cylinders and piston heads.

Horizontal machining, often referred to as milling, uses rotating cutting tools to remove material from a workpiece. This process is performed on a horizontal machining center (HMC), where the spindle is positioned parallel to the ground.

Since the spindle is horizontal, the cutting tools extend sideways and cut across the side of the component. One significant advantage of this setup is that chips naturally fall away from the work area, keeping the table cleaner and improving cutting efficiency.

SGK operates 12 HMCs manufactured by ACB.

Vertical machining is similar to horizontal machining; however, in a vertical machining center (VMC), the spindle is positioned vertically.

Because the spindle is vertical, the cutting tool points straight downward from the tool holder and usually operates on the top surface of the component. This setup is commonly used for operations such as face milling, slotting, drilling, and contouring and is widely preferred for its simplicity and flexibility.

SGK operates 10 VMCs manufactured by ABC Company

Turning helps reduce the diameter of a part to the required size while also providing a smooth surface finish. A turning center is a CNC lathe that is controlled by a computer to ensure better accuracy and consistency. Modern turning centers are highly advanced and can perform milling and drilling operations in addition to conventional turning, making them highly versatile.

SGK operates 10 turning centers manufactured by ABC Company.

SGK’s state-of-the-art robotic production line is a manufacturing setup in which NACHI industrial robots automatically handle various stages of the production process. Instead of relying heavily on manual labor, these robots are programmed to perform tasks such as loading and unloading parts, machining support, assembly, and inspection.