2011 together we make it happen - alicon...

2011 Together We Make It Happen

Casting The Future

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Casting The Future

• Sales Rs. 25667 Lacs.

• One of the Largest Aluminium foundry in Low Pressure (LPDC) & Gravity Die

casting (GDC) in India.

• Core Competence.

Design of LPDC , GDC & Sand casting Parts.

Faster development of Prototype Parts.

In house Testing Facilities.

Casting Simulation.

• Casting for Automotive, Locomotive, Medical, Energy , Defense and Agricultural

segments.

alicon is involved in Design, Engineering and Casting of Aluminum

Components.

alicon

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Casting The Future alicon

• To serve the customer with low & high volume parts from India locations.

• Proven track record for cost competitiveness learning’s from Indian Market.

• One of the Largest foundries in LPDC & GDC process in India which offers frugal

engineering solutions.

• Pioneer Users of Pro-Cast in India.

• Capabilities of Handling both Low and High Volume.

• De-risking customers from currency fluctuation.

• Providing the better options by using strengths & ability of both organization

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Casting The Future alicon Castalloy in India

Alicon Castalloy Limited, Shikrapur,

Pune.(1995)

Alicon Cast alloy Limited Binola,

Haryana. (2006)

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Hero Honda, Honda Motor,Suzuki ,

Sona Koyo,.

Maruti Suzuki, Bajaj Auto, Tata

Motors, Honda siel Cars, Mahindra

Greaves, Eicher, Royal Enfield, GE

Medical, Knorr Bremse, Tata Motor


Casting The Future alicon Global & Domestic Customers

Two Wheeler OEM Four Wheeler OEM Tier 1 & Non Auto

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http://www.google.co.in/imgres?imgurl=http://www.brandsoftheworld.com/brands/0019/4306/brand.gif&imgrefurl=http://www.brandsoftheworld.com/countries/in/194306.html&h=200&w=200&sz=4&tbnid=YGiQBfwQbbtgxM:&tbnh=104&tbnw=104&prev=/images?q=Ashok+Leyland+logo&hl=en&usg=__exXBc1nDpzRd8HKHmwaufxJa3sQ=&ei=M1nhS_CQDci3rAfGnIDWAg&sa=X&oi=image_result&resnum=1&ct=image&ved=0CAwQ9QEwAA

http://www.google.co.in/imgres?imgurl=http://tribe.virgin.com.au/blog/wp-content/uploads/2009/04/fiat-logo.jpg&imgrefurl=http://tribe.virgin.com.au/blog/&usg=__mOiGg0-MMaapg53sueIXcPaM3WI=&h=1298&w=1298&sz=644&hl=en&start=7&um=1&itbs=1&tbnid=iqbNLbDbUDumaM:&tbnh=150&tbnw=150&prev=/images?q=fiat+logo&um=1&hl=en&tbs=isch:1


Casting The Future Sales Performance

Sales value in Rs. Lacs

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18860 19780 18400

21210

25667

35500

0

5000

10000

15000

20000

25000

30000

35000

40000

2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 (Estimated)

Rs in Lacs.

Rs in Lacs. Linear (Rs in Lacs.)


Casting The Future

Alicon Castalloy Limited. , Pune,

India

Alicon Castalloy Limited. Binola

Alicon Manufacturing facilities

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Alicon Castalloy Limited. Shikrapur Pune


Casting The Future Plant facilities

Core Shop Facility Tilt GDC Die Casting Facility Cell - Casting & Machining

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Casting The Future

Cylinder Heads Cylinder Heads for Motor Cycle

Cylinder Heads for Racing bikes Passenger Car

Product Gallery

Cylinder Heads for Commercial Vehicles

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Casting The Future

Engine Mounting Brackets EGR Valve

Product Gallery

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Casting The Future

CAC Tanks ( Radiator Intake & Outlet for Paccar & MAN Trucks) Rack Housing

Intake Manifold

Product Gallery

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Casting The Future

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Casting The Future

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Alicon R & D Promise

• Collaborate Innovation, Co-creation

& Sustainable business in Light

Alloy Castings.

Grow the Society to make India

Proud.

Create Art to Part by Innovative

Ideas

Induce Indian Intelligence to

develop new Technology.

Generate new employment by

developing new Innovative

Products.

Develop product for Green &

Clean Environment.

Increase Export market & Develop

Import substitute.

Develop best Technology across

the globe for Low Pressure and

Gravity Die castings.

VISION

OBJECTIVES MISSION


Casting The Future

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Sr. Location Area in Sq. Mtr

1 R & D Lab 140.95

2 R & D Design Office 451.25

3 R & D Tool Improvement Room 303.87

4 R & D LDPC Pilot plant 188.28

5 R & D GDC Pilot plant 405.38

Total 1489.73

R & D Centre – Floor Plan with area in sq. Mtrs


Casting The Future

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R & D Testing Lab


Casting The Future

Spectrometer CMM Profile Projector

Millipore Testing Contour Measure Microscope Hardness Tester

Farro Arm

R & D Equipments

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Casting The Future

Hot Tensile Testing Sieve Shaker Muffle Furnace

Core Gas Determination Bending Strength Testing

Scratch Hardness Tester

X-Ray Salt Spray Testing

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R & D Equipments


Casting The Future

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R & D Office


Casting The Future

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R & D LPDC Cell ( Pilot Lot)


Casting The Future

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R & D GDC Cell ( Pilot Lot)

Core Shooter GDC Machine


Casting The Future

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R&D Manpower with Educational Status

Slno Category Nos

1 Doctorate 0

2 Master Degree 2

3 Graduates / Engineering

Graduates 7

4 Diploma Holders 64

5 Others 14

Total 87

Present

Slno Category 2011-12 2012-13 2013-14

1 Doctorate 0 1 1

2 Master Degree 2 5 8

3 Graduates / Engineering

Graduates 7 15 25

4 Diploma Holders 64 75 92

5 Others 14 26 32

Total 87 122 158

Future


Casting The Future

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Product Development Cycle


Casting The Future

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Product Development Cycle


Casting The Future

CAD

AutoCAD

Catia V5 R17

UG NX-4/5

Pro – Engineer Wild

Fire 2/3

Soild Works

Auto Desk Inventor

2009

CAM

Delcam

Catia Machinist

CAE

LS Dyna

Hypermesh

Pro-Mesh

Pro Cast

Magma

P D M

Wind Chill 8.0

Create Art to Part by creating Innovative Ideas by some software used 3D Modeling based Design survive capable of

designing from concept through Specification, tool design & validation.

R & D Capabilities

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Casting The Future Simulation work samples

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Fraction Solid_Cyc03.avi


Casting The Future

Changed to LPDC after

PROCAST

Analysis to Increase Productivity &

Eliminate Defects

Converter Housing for AVTEC Ltd.

(Aprox. Wt-17.5 Kg)

Suitable for GDC

Casting Simulation for LPDC process

using PROCAST

Design & Simulation

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Casting The Future

Rapid Prototyping (Objet and LOM method)

Prototypes based on resin

Max. size 320 x 320 x 200 mm

Presentation- and functional models

Model construction – Rapid Prototyping – Casted product Thin Wall Casting 1.8mm

CAD system

Pro-Engineer Wildfire 2

Interface for Step Iges VDA and others

Tool design Magma casting simulation

Rapid Prototype Development

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TECHNOLOGIES

• Gravity die casting

• Sand casting

• Low pressure die casting

• Rapid prototyping

• X ray Inspection

• CAD – Pro Engineer

• Magma casting

• Solidification

ALLOYS APPLIED

• Al Si 7 Mg Al Si 9 Mg

• Al Si 10 Mg

• Al Si 12

• Al Si 12 Cu Ni Mg

• Al Si 8 Cu 3

• Al Si 6 Cu 4


Casting The Future

7 5

2 3

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TOOL DESIGN FEA & CFD FOUNDRY SIMULATION

REVERSE ENGINEERING 3D CAD MODELLING CAD DRAFTING

1

CAD CONVERSION

4

8

TECHNICAL MANUALS

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R & D Analysis Activities


Casting The Future

FORGING DIES LPDC DIE CAST DIES FEA – THERMAL ANALYSIS 3D MODELLING EXTRUSION DIES

FEA – STRUCTURAL FEA – MESHING DRAFTING & DETAILING TECHNICAL MANUALS

PRODUCT ENGG CASTING SIMULATION WEIGHT OPTIMIZATION EXTRUSION SIMULATION

WHITE LIGHT SCANNING

HPDC DIE CAST DIES

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Simulation


Casting The Future

R & D ACHIEVEMENTS


Casting The Future

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DEVELOPMENT OF MAIN BATTLE TANK WHEELS

FOR

MINISTRY OF DEFENCE, GOVT. OF INDIA


Casting The Future

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Arjun Main Battle Tank

Tank weight reduced by 4.1 Tons, Speed Increased by 20 Km/hr.


Casting The Future

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Arjun (Mark-2) New version Main Battle Tank



Casting The Future

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T 72 Main Battle Tank



Casting The Future

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Abhay Infantry fighting vehicle

India’s indigenously developed


Casting The Future

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T -72 Bridge Layer Tank


Casting The Future

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DEVELOPMENT OF MRI SCANNIG MACHINE PART

(MAGNETIC RESONANCE IMAGING)

GE HEALTH CARE,


Casting The Future

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Front support and Foot switch

Machine rotates 3000 RPM


Casting The Future

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Smart Cathode

Machine rotates 3000 RPM


Casting The Future

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MRI SCAN Machine


Casting The Future

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Electrical Environment friendly CAR


Casting The Future

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Gear Box Casing

LPDC

Earth Moving Equipment Part


Casting The Future

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Converted Steel Bracket to Aluminium


Casting The Future

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Gas Turbine Power Generation Parts


Casting The Future

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Product Gallery – India


Casting The Future

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Intake Manifold

GDC



Casting The Future

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Casting The Future

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Casting The Future

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Combine Manifold with Cylinder head Cover


Casting The Future

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Doorlock

Weight: 0,30 kg

Gravity die

casting

Console

Weight: 0,4 kg

Gravity die

casting

Valve housing

Weight: 7,3 kg

Gravity die

casting

Housing

Weight: 1,4 kg

Gravity die casting

High Speed railway breaking system Parts


Casting The Future

Year 2008-09

No. of RFQ’s 79

Regretted RFQ’s 10

Quoted 58

Order Hit 11

Win RATIO (%) 19

Year 2009-10

No. of RFQ’s 414


Quoted 245

Order Hit 75

Win RATIO (%) 31

Business Finalized “Win Ratio”

Year 2010-11

No. of RFQ’s 210


Quoted 149

Order Hit 62

Win RATIO (%) 42

0

20

40

60

Year2008-09

Year2009-10

Year2010-11

Year2011-12

1931

42

11.83

Ratio %

Year 2011-12

No. of RFQ’s 182


Quoted 169

Order Hit 20

Win RATIO (%) 11.83%


Casting The Future

Brackets – 10 Parts

Manifold – 1 Part

Year 2011/12

Year 2011/12

Year 2011/12 BFT – 1no

Cyl Head – 1no

Pipe – 2nos

Adaptor – 1no

Bracket – 2 nos

Manifold – 1 nos

Year 2011/12 4 Parts –

IM, Cam Box

4 Parts :

Cyl. Head, Block &

Cover Year 2012 G30 Project

Cylinder Head – 6 nos

BFT – 2 nos

Year 2011 Cylinder Head – 1 no

Year 2012

New Parts added - Automotive

http://images.google.co.in/imgres?imgurl=http://www.blogcdn.com/www.autoblog.com/media/2009/01/xylo_580.jpg&imgrefurl=http://www.autoblog.com/2009/01/18/mahindra-introduces-xylo-suv-but-renault-tie-up-in-jeopardy/&usg=__IsjDzIEdgv6BuD55MZNceAUQHN8=&h=328&w=580&sz=44&hl=en&start=11&um=1&itbs=1&tbnid=b6FsfrR2tMcCbM:&tbnh=76&tbnw=134&prev=/images?q=xylo+mahindra+for+USA+market+pictures&um=1&hl=en&tbs=isch:1

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Casting The Future

Housing – 3 nos

Cover – 3 nos

Year 2012

Year 2012

11 Parts

Cover & Housing

Year 2012 4 parts

Housing, manifold

& Cover

New Parts added – Non -Automotive


Casting The Future R & D Ongoing Projects

AREVA- Holder Contact Sphere

BEHR- Renault Air Right Tank

BEHR- Renault Air Left Tank

Haldex Concentric Pumps- Oil Pump Housing

BEHR- Scania Air Right Tank

BEHR- Scania Air Left Tank

New Product

Development

New Product

Development

New Product

Development

New Product

Development

New Product

Development

New Product

Development

Under

Process

Under

Process

Under

Process

Under

Process

Under

Process

Under

Process


Casting The Future R & D Ongoing Projects (Status)

JCB- 4.8 Ltrs Intake Manifolds

MSIL- OMNI Intake Manifolds

Vikas Ensa- Neptune 4 cyl Housing

Vikas Ensa- Neptune 6 cyl Housing

Piaggio- Oil Sump

MSIL- YG4 Intake Manifolds

New Product

Development

New Product

Development

New Product

Development

New Product

Development

New Product

Development

New Product

Development

Under

Process

Under

Process

Under

Process

Under

Process

Under

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Under

Process


Casting The Future R & D Projects (Future)

Ingersoll Rand- Manifold

Harley Davidson – Cylinder Head Rear

Harley Davidson – Cylinder Head Front

Siemens- Housing FA X S3

Siemens- Housing Cable Termination

Siemens- Housing 2/3 X S2

New Product

Development

New Product

Development

New Product

Development

New Product

Development

New Product

Development

New Product

Development

2012

2012

2012

2013

2013

2013


Casting The Future R & D Projects (Future)

Siemens- Cover S2/S3(Rectangular)

Siemens- Cover 2/3 X S2/s3

Harley Devidson- Cylinder Front/ Cylinder Rear/ Cyl Head Front/

Cyl Head Rear

HSCI-Air Intake Manifold/ Inlet pipe/ Outlet Pipe /Inlet Water/

Outlet Water/ Outlet cooler/Inlet Cooler/ assly Inter cooler Inlet/

Assly Inter cooler outlet

Tata Cumins- Fly wheel Housing

New Product

Development

New Product

Development

New Product

Development

New Product

Development

New Product

Development

2013

2013

2013

2014

2014


Casting The Future

2011 together we make it happen - alicon...

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