• Piston Manufacturing Machine: This machine is available in four models-GC 65, GC 100, GC 140 and GC 175. So far we have supplied over 35 machines to several piston companies. In these machines only metal pouring and piston removal are manual. All other die and machine movements are automatic
• Gravity Die Casting Machine: (Type-GCX1) We also supply die casting machines and dies for any non-ferrous casting for all types of applications. These machines also have automation to the same extent
• Piston Dies: We design and manufacture dies for the manufacture of any kind of piston to suit the above machines or any other type of machine. We have so far made over 25 dies, ranging from 35 to 165mm in diameter
• Circlip Grooving Machine: It is made in 3 models. These machines are highly productive. Piston is held manually and the grooving time is 1.3 to 3.9 seconds only
  

• The core is basically a 5-piece construction. In addition, we have other die parts such as crown, moulds etc.
• Hydraulic cylinders are used to give movements to moulds, eye pads, crowns, locks, tiltings, etc.
  
• We use PLC from SIEMENS, Germany, which provides complete control of the machines. All movements are obtainable in manual mode also
• During automatic cycle – metal pouring, ring placing and piston removal are manual. All other tool movements during assembly and disassembly, including air/water cooling, are automatic.
• AS-CAST CROWN piston can be made on the machine
• Both RC and non-RC pistons can be cast on the machine
• The machine is complete in all respects consisting of power pack, hydraulic cylinders, direction control valves, PLC, pendent control, proximity switches etc.
• The machine is provided with motorized central lubrication system which delivers the right amount of oil to all the sliding surfaces without fail  in every 2 hours.

Special Features

Model GC 175

• This is a single cavity piston die casting machine to cast pistons in the range of 140-175 mm diameter
• The machine bed has been provided with up down tilting feature to ensure metallurgically sound casting. Bed is tilted up during pouring
• Hydraulic power pack with 7.5 HP motor, 55 LPM pump and oil cooler is a part of the machine
  

Model GC 140

• This is a single cavity piston die casting machine to cast pistons in the range of 70-140 mm diameter
• The machine bed has been provided with up-down tilting feature to ensure metallurgically sound castings. Bed is tilted up during pouring
• Hydraulic power pack with 7.5 HP motor, 55 LPM pump and oil cooler is a part of the machine.

• This is a twin cavity piston die casting machine to cast pistons in the range of 65-100 mm diameter
• Hydraulic power pack with 7.5 HP motor, 55 LPM pump and oil cooler is a part of the machine
• The core is basically a 5-piece construction. In addition we have other die parts such as crown, moulds etc.

Movement
The following movements are provided on the machines:

• Mould: Two mould halves have two independent movements. Each has a travel capacity of 250 mm. The maximum distance between two halves is 500 mm. The two halves are guided and held down on the bed on hardened guide ways. The maximum die surface available at the parting plane is 400 mm in length and 350mm in height. The maximum die thickness can be 150 mm. Ejector plate design can be provided on either or both the halves. Shell core placing is manual and the die must have suitable design for the purpose
• Top Core: The minimum and maximum distance between the top core provided and the bed surface, is 300 mm and 600 mm
• Bottom Core: The minimum and maximum distance between the bottom core provided and the bed surface is 0 mm and 80 mm
• Rear Core: Rear core is also provided with a travel of 100 mm
• Tilting: The main bed carries the die tilts up and down during the automatic cycle. The speed of movement is adjustable independently in both the directions. The angle of tilting is also adjustable between 0 and 45 degrees.

Hydraulics
The machine is supplied with a hydraulic power pack of 250 litres tank, 7.5 HP motor, a gear pump 45 LPM, relief valve, heat exchanger etc. complete in all respects. All movements are given by hydraulic cylinders  operated by solenoid controlled valves.

Controls and Automation
The machine works semi-automatically. Shell core placing, metal pouring and picking up the casting are manual. Complete cylinder/die movements, cooling of various areas, cycle time etc. are automatic. In manual operation each cylinder can be operated manually and   independently as well. Selector switches are provided to include or delete top core, rear core and bottom core depending on the requirements of the particular component to be cast. Two of the solenoid controlled water cooling valves are provided  for die cooling. The duration of cooling is adjustable through electronic timers. We use SIEMENS S7-200 series PLC in the machines for all controls and automation.

General
The machine is provided with hand operated  centralized lubrication system. The overall floor space occupied by the machine is 2600 mm by 1500mm. The maximum height is 2000 mm. The approximate weight of the machine is 1450 kilogram.

• The spindle head mounted on a pedestal has inner and outer spindles running eccentrically, one inside another, at different speeds, in another stationary sleeve. When foot switch is pressed the inner spindle carrying the cutting tool makes the groove, while running eccentrically. After the completion of groove cutting the drive is automatically cut-off for both spindles and the tool is brought  to a stop accurately in retracted condition for piston to be taken out
• The specialty of this machine is that it is provided with one pair of Electro-magnetic clutch and brake for starting and stopping of the drive for each cycle while the motor is continuously running. Normally a brake motor is used in such an application which burns out frequently due to the high rate of on-off cycle
• The piston is supported on the stationary sleeve along the complete length of the pin bore and held in hand. The inserting and removal of the piston is also by hand.