Galaxy Metal Cast - Manufacturer & Exporter Of Wet & Dry Type Cylinder Liners, Sleeves And Air Cooled Blocks.

Foundry

Melting process is carried out by 2 crucibles by dual track induction melting furnaces with continues monitoring melting process by Pyrometers and Spectrometer.The most commonly used melting system is the induction crucible furnace. The induction crucible furnace has a crucible which heated by an induction furnace coil surrounding the crucible.

Furnaces : 2Nos

Capacity: 300Kg/Each

Melting Capacity: 250 tons/month

This process based on the centrifugal force principle and required of the liner is achieved with particular die. We have in house centrifugal casting die facility. The process is so essential for liners and sleeves because it provides very dense structure, ultimately increase the life of liner and performance of the engine.

Process is pollution / smoke and noise free, ensuring fine result and excellent mix. This also eliminates the possibility of hidden porosity, blow holes and casting defects common to predictable castings. The castings produced by a combination of induction melting and centrifugal casting processes are superior, consistent and have better microstructure.

Proof Machining

Proof machining is an important step in the manufacturing of cylinder liners as it helps to ensure that the final product meets the required dimensions and tolerances. By verifying the dimensions before proceeding with final machining, manufacturers can save time and materials by avoiding the need for costly rework.

Our Machine shop is well equipped with CNC & SPM machine, along with heavy duty Latch Machines. Rough & Semi Finish machining done by heavy duty Lath Machine and Fully Finish is done by CNC machine to give high accuracy in dimensional parameters, Surface roughness & Geometric parameters. We are also having SPM for Outside & Bore machining combine operation.

Boring

Fine boring is a process used to create a precise and accurate cylindrical hole with a smooth surface finish. In the manufacturing of cylinder liners, fine boring is used as a finishing operation to achieve the final dimensions and surface finish of the liner bore.

Fine boring is a critical process in the manufacturing of cylinder liners, as it helps to ensure that the liner bore has the precise dimensions and surface finish required for proper function and durability. By using advanced cutting tools and precise machining techniques, manufacturers can produce cylinder liners with excellence.

Boring Operations done by Vertical Boring Machines Centre (Super Wolga) to maintain dimensional accuracy, taper, Ovality and Surface finish.

CNC Final Machining

The CNC outer diameter process is a critical step in the manufacturing of cylinder liners as it helps to ensure that the final product has the precise dimensions and surface finish required for proper function and durability.

By using advanced CNC machines and precise cutting tools, we are able to produce cylinder liners with excellent accuracy and surface finish.

Grinding

Grinding is the process where super surface finish can be maintained on products. Grinding controls dimensional parameters, surface parameters and geometrical parameters.

We have two type of grinding process center less grinding and cylindrical grinding.

We do grinding using a centerless grinding machine to achieve the final outer diameter and surface finish of the cylinder liner.

Plateau Honing

Plateau honing is a precision honing process used in the manufacturing of cylinder liners to achieve a specific surface finish and geometry on the liner's bore.

We bore the liner's bore using a set of honing stones (Dimond) that are specifically designed for the plateau honing process.

Honing Process done by honing machine, our cylinder Liners bores are cross honed and diameters are properly ground finish to achieve the highest level of accuracy and Surface roughness as per customer specifications.

Final Inspection

In final inspection we maintain & checked all parameter as per standard drawing. We have Digital micrometers, Digital vernier , Boregauge, Roundnesstester & pneumatic Plug gauge, pneumatic ring gauge which fullfill the final inspection criteria.

Our Final inspection departments is well experience and well equipped by all instruments. It consists of inspection the surface of the casting with naked eye or sometimes with a magnifying glass or microscope.

It can only indicate surface defects such as blow holes, fusion, swells and external cracks. Almost all castings are subjected to certain degree of visual inspection.

Laser Marking

We have Laser Marking machine for traceability and mark the Logo. Neat, Clean & Indelible markings of Logos & Part no. are marked which doesn’t produce stress or change in physical properties of materials. Marking are proof from chemicals, water, Oil, Grease and other fuels.

Our machine have higly accurate and presice marking capability.

Packing & Dispatch

Cleaning machine to clean the Cylinder Liners and Sleeves before the packing. Finish Cylinder Liners are duly Oiled & placed in VCI paper and packed in corrugated box as per customer requirements.

Safe, quick and undamaged - that's how our products reach any destination all round the world.

To assure comprehensive quality methods that prevent damage in transit, because what matters is to deliver the components safely to the end user in the quality in which Galaxy Metal Cast produced for them.

Production Facilities