Innowerx Manufacturing Services Private Limited

Rabale, Navi Mumbai, Maharashtra

• Process Overview – It is a process that creates a desired shape and size by removing the unwanted material from a larger piece of metal i.e Subtractive Manufacturing. A plethora of machining options are available depending on the part geometry, profile to be achieved, GD & T requirements, surface finish, throughput etc. CNC (Computer Numerical Controlled) machining is a widely used manufacturing process that uses automated high-speed cutting tools to form a particular feature from metal or plastic. CNCs are generally classified as 3-axis, 4-axis and 5-axis based on the movement of part and tooling along the axis. Different machines have different working mechanisms such as : a) workpiece securely clamped while the tool moves b) tool may remain in place while the workpiece moves c) both the cutting tool and workpiece move together.

• Capabilities

  • Prototype to high volume production of up to thousands of parts per year based on part configuration

  • CNC machining of parts weighing up to 10 Tonnes

  • CNC machining of parts measuring up to 1000mm Dia and 4000mm Length

  • Small and big sized VMC machines up to X axis – 4000mm, Y axis – 2000mm and Z axis – 1000mm

  • Cylindrical Grinding of parts up to 800mm Dia and 6000mm Length

  • Conventional turning of parts up to 1500mm Dia and 6000mm Length

  • Supporting machining operations such as Cutting, Deep hole drilling, Milling, Boring, Broaching, Gear hobbing, Surface grinding etc.

  • Machining of wide variety of material grades such as Carbon steel, Alloy steel, Tool steel, Non-ferrous alloys, and Superalloys

  • Machining of castings and forgings of small to large sized parts

  • Tight tolerance of machined parts up to ± 0.005mm

  • Post-machining surface finishing operations such as ID and OD polishing, Superfinishing, Honing etc.

  • Surface treatment processes such as plating, anodizing, phosphating, blackodizing, thermal spray coating, slurry coating, polymer painting etc.

  • CMM inspection for part validation and approval of machined parts

  • ERP notified calibration control system for measuring/monitoring instruments and machines

  • In-house lab tests carried out for raw material verification at production site, certified to NABL standards

  • Complete NDT testing of parts for defect analysis pre and post machining as per international standards

  • Customer appointed third party inspection and verification allowed

  • Manufacturing facility certified to IATF 16949 and AS 9100 Rev.D Quality Management System

  • Implementation of Lean Six Sigma tools for better quality control, process control, part traceability and documentation

  • Industry 4.0 integrated manufacturing facilities

• Application and Benefits

  • We supply machined components to almost all industry sectors in batch and mass production quantities. The design and functional characteristics of the part are fixed based on its end application. Selection of the material is done to sustain the working environment and machined to accurate dimensions to ensure proper fit and assembly.

  • Usually, Aerospace engine parts are made from Titanium, Tantalum and Nickel based alloys which exhibit high strength, low weight and high temperature fatigue resistance

  • Similarly, parts used in Oil & Gas and Power Generation sectors are made from Nickel, Chrome and Cobalt based alloy steels which exhibit high wear and corrosion resistance

  • Few key benefits of machining include :

    • Rapid Tooling – A variety of materials can be machined to achieve accurate dimensions for making fixtures and molds.

    • Rapid Prototyping – Flexibility of manufacturing small scale prototypes saves a lot of time, money and effort and enables to conduct a detailed part validation and risk assessment

    • Production – Reliability and Repeatability of machining can be ensured by application of advanced process control techniques which enables mass production

    • Customization – Wide range of advanced manufacturing techniques increases the scope of customization for new part development

Forging is a manufacturing process involving the shaping of metal using localized compressive forces of a hammer or a die (Open Die & Closed Die). Forgings are broadly classified based on the temperature at which it is formed as Cold, Warm & Hot forging. For the latter two, the material is heated up to a certain range of temperature. Depending on the type of die used, the Closed die shall provide better dimensional control and strength. To meet the increasing demand for customized part requirements many new forging technologies have evolved such:

• Ring Rolling – It is used to produce seamless rings varying in size from a few inches in diameter and weighing less than a pound to over 20 feet in diameter
• Radial Forging – Part is forged with the help of four dies arranged in one plane acting simultaneously in radial direction
• Orbital Forging – Part is held in a die cavity and forged by compressive forces of the upper die revolving on an inclined axis
• Upset Forging - It involves locally heating a metal bar and then, while holding it firmly with special tooling, applying pressure to the end of the bar in the direction of its axis to deform it
• Extrusion Forging – It is done by deforming metal and flowing it into a chamber, and then compressing the metal while it is inside the chamber at extreme temperatures

Capabilities

• Prototype to high volume production of up to thousands of parts per year based on part configuration
• Forging of parts from few Kgs up to more than 10 Tonnes
• Manufacturing of wide variety of material grades such as Carbon steel, Alloy steel, Tool steel and Superalloys
• Gas and Electric operated Heat Treatment furnaces for heating of pre-form as well post heat treatment such as Annealing, Normalizing, Hardening, Tempering etc.
• Up to 4000 Tonnes fully automatic Hydraulic press
• Mobile charging machines and forging manipulators
• Flexibility of end-to-end machining of small to large sized parts
• Tolerance of close die forged parts up to ± 0.25mm based on the characteristics of the part and machined tolerance of up to ± 0.02mm
• CMM inspection for part validation and approval of machined parts
• In-house lab tests carried out for raw material verification at production site, certified to NABL standards
• Complete NDT testing of parts for defect analysis as per international standards
• Manufacturing facility certified to IATF 16949 and AS 9100 Rev.D Quality Management System
• Globally approved system, client, and product certifications

Application and Benefits

• A variety of forged parts are used in the Aerospace and Defence industry specifically made from Aluminum alloys, Alloy steels, Superalloys, and composites. Few of them are shafts, turbine blades, torpedo’s, canisters, domes, missile launchers etc.
• Common applications in Oil & Gas, Valve and Power Generation sector include flanges such as weld-neck, rolled, lap-joint flange; rings and connectors such as seat ring, labyrinth ring, seal ring retainer ring, body adapter etc.
• Other general engineering applications include shafts, gears, pistons and cylinders, transmission parts etc.
• Forgings are used particularly in critical applications where the parts are subjected to extreme operating environment. Few of their benefits over castings are listed below:

1. Higher strength, toughness, and structural integrity
2. Longer service life
3. Higher design stresses
4. Increased safety due to ductility
5. Greater strength to weigh ratio
6. No porosity