COLD FORMING
Cold forming is the process of deformation of metals at room temperature. The metal wire is cut off to required length and deformed at room temperature by inserting it into carbide or steel dies in 2 or more stations. In this way, we can obtain highly complex parts at high speeds which are near net shape.
We produce cold-formed parts with detailed planning processes, precise engineering, and simulations with various materials such as Aluminum, Brass, Copper, Steel, and Stainless Steel on our modern and efficient machines with up to 6 Cold Forming Stations and also vertical presses.
1. High volume can be achieved
2. Added material strength
3. Tight tolerance and critical specification
4. Near net shape
5. Cost saving up to 40%
6. Consistent, reliable quality at high tolerances
7. Increased tensile strength with work hardening
8. Improved grain structures
9. High-speed manufacturing process
The applications of cold forming are vast and can be used to produce a wide range of products.
Only after the precise analysis of the material, its specification, and structure it is processed in the forming machine, not loading the material beyond its specific tensile strength, to avoid cracks and defects in the material during structural change.
MACHINING
Machining is a versatile process with numerous applications and possibilities to produce, complex geometries can be produced. It is economically feasible for small quantities. With the use of CNC and VMC machines combined with a highly skilled workforce, the possibilities are limitless.
These processes will markedly help in future projects by producing accurate and precise parts. Numerous other components like alternator shaft, rotor shaft etc. are also included in our line of products.
1. CNC long-and short-turning machines with 5 axes
2. Machines with pull-down chuck and collet chuck
3. Production of high-complex turned parts
4. Automation through conveyer and Karakuri Kaizens ( Gravity-based mechanism)
In the future most machining processes will be automated and integrated with Industrial 4.0 with the help of the Internet of Things (IoT) and Artificial Intelligence(AI) which can be used for a variety of processes thus avoiding breakdowns and other losses.
GRINDING
At Ramsays Corporation we can produce various types of components, with high surface finish and gear profiles with our modern technology and machinery. Our products are manufactured to the highest quality with the latest standards available, always looking for new possibilities to produce our products economically.
We have the capabilities of both cylindrical and center-less grinding. With these machines and highly sensitive in-process gauges (Marposs), we can achieve very close tolerances of ±1 micron. Depending upon the areas of application cylindrical or center-less grinding is used. These machines allow us to provide high quality, dimensional and shape accuracy in our products.
1. Short & Long shaft grinding with up to 3 micron tolerance
2. All these grinding processes are Centre to Centre
3. Production of high-complex ground parts
4. Automation through conveyer and Karakuri Kaizens ( Gravity-based mechanism)
1. Short & Long grinding with up to 3 micron tolerance
2. Cylindricity of 1 micron can be achieved in our grinding machines
3. Product accuracy with surface finish of Ra 0.08
HOBBING
Hobbing is one of the most fundamental processes in gear manufacturing. With highly advanced machinery and intelligent automation we are able to produce spur and helical type gears with high accuracy.
1. Automation of part loading and unloading
2. Machines capable of producing spur and helical gear components
3. Product accuracy of Din 4 to 6
HEAT TREATMENT AND SURFACE TREATMENT
Heat treatment and surface treatment are fundamental processes done to enhance the physical and chemical properties of the products as per the customer requirements.
• Continuous Mesh Belt furnace
• Sealed quench furnace
• Induction Hardening M/C
• Zinc trivalent yellow passivation
• Zinc cobalt yellow passivation
• Zinc iron trivalent black passivation
• Nickel plating