· pdf fileprocast analysis to increase ... hpdc sand castings investment casting ... 2012 ...

www.alicongroup.co.in

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2012 Together We Make It Happenwww.alicongroup.co.in

Casting The Future

FULL SYSTEM SOLUTIONS

System Solution Capabilities : alicon group

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Casting The Future

‣India Group Sales USD 107 million .

‣One of the largest aluminum foundry in India & having manufacturing facilities in Austria and

Slovakia also for Global Customers.

‣ Joint Venture with Enkei Corporation (Japan)

‣ Technical Collaboration with Hekikai Koki (Japan)

‣Core Competence:

• Rapid Prototyping

• Designing (CAD/CAM/CAE/Simulation)

• In house Tool Manufacturing

• Die Casting (Sand Casting/GDC/LPDC)

• Machining, Assembly & Painting.

‣Casting for Automotive, Locomotive, Medical, Energy and Agricultural segments.

alicon group is a consortium of companies involved in Design, Engineering and

Casting, Machining & Assembly of Aluminum Components with global foot prints.

alicon group of companies

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Casting The Futurealicon group promises

Utilize the best of European engineering, Japanese quality & Indian ingenuity to produce exceptional and innovative aluminum casting products.

Our goal is to bring all group companies together, pooling the collective resources to provide the customer

with best-in-class products.

Become the globally preferred supplier

for Light Alloy Casting Solutions

Ensure total customer satisfaction

Grow the employees, associates and

suppliers

Increase shareholder value

Quality, Integrity and Respect

Encourage Entrepreneurship,

Ownership and Accountability

Commitment to the Environment and

Community

VISION : MISSION : VALUES :

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Casting The FutureGlobal Presence

•Atlas Castalloy Ltd (1969)

•Alicon Castalloy Ltd, Pune (1995)

•Silicon Meadows Design Ltd.(1996)

•Alicon Castalloy Ltd, Binola (2006)

•Silicon Meadows Engineering Services Ltd. (2009)

USA EUROPE

INDIA

•Silicon Meadows Engineering

Services, Nashua, USA

•Illichmann Castalloy GmbH, Austria

•Illichmann Castalloy s.r.o. Slovakia

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Casting The Futurealicon presence in India

Proposed

Alicon Castalloy Limited Pantnagar -

Uttaranchal.

Atlas Castalloy Limited, Chinchwad, Pune

(1969)

Silicon Meadows Design Limited,

Chinchwad, Pune (1996)

Alicon Castalloy Limited, Shikrapur,

Pune.(1995)

Silicon Meadows Engineering Services

Limited, Viman Nagar, Pune. (2009)

Alicon Castalloy Limited Binola,

Haryana. (2006)

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Casting The Future

Zarnovica / SLOVAKIAGDC,SAND Castings

Altmünster / AUSTRIARapid Proto Castings (RPT) & LPDC

Illichmann facility-Austria & Slovakia

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Casting The FutureSales performance: alicon group, India

sales value in US$ (Mn)

Year 2010-11

* Enkei wheel division formulated as a separate company from April.2010 onwards

DUNS No :- 650653579

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Casting The Futurealicon group global & domestic customers

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Two Wheeler OEM Four Wheeler OEM Tier 1 & Non Auto

http://www.google.co.in/imgres?imgurl=http://www.mototype.com/pics/5243/full/ktm_logo_1.jpg&imgrefurl=http://www.mototype.com/pages/2813/ktm&h=306&w=780&sz=18&tbnid=tcubEDIIfGZhtM:&tbnh=56&tbnw=142&prev=/images?q=KTM+logo&hl=en&usg=__QMNDR1yDPyTgUKw8zmUl8Cf457U=&ei=dm3ES5rVD8L78Aaw6bCtDw&sa=X&oi=image_result&resnum=2&ct=image&ved=0CAgQ9QEwAQ

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

http://www.google.com/imgres?imgurl=http://charlescarservice.com/volkswagen-logo.jpg&imgrefurl=http://charlescarservice.com/&h=1000&w=1000&sz=137&tbnid=ttKZkirj6Y3tLM:&tbnh=149&tbnw=149&prev=/images?q=volkswagen+logo&zoom=1&hl=en&usg=__w7ofoNpfQnc_wPl7N3nm-zcceE0=&sa=X&ei=znV3TL-qFY-8vQOZluy7Bg&ved=0CAoQ9QEwAg


Casting The Future

Atlas Castalloy Limited -

Chinchwad, Pune, IndiaAlicon Castalloy Limited. , Pune,

India

Alicon Castalloy Limited. - Binola,

India

alicon group facilities,India & Europe

Illichmann Castalloy,

GmbH & s.r.o

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Casting The Future

Testing Facility Including X-Ray,

Pune, IndiaMachining Facility, Pune, India

Silicon Meadows Engineering

for Export Projects

Silicon Meadows Engineering,

Pune

Silicon Meadows Design Center,

Pune, India

Silicon Meadows Die

Manufacturing, Pune, India

alicon group facilities,India & Europe

Rapid Prototyping at

Illichmann

Rapid Prototyping at

Illichmann

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Casting The FuturePlant facilities – India & Europe

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

Core Shop Facility, Europe Tilt GDC Die Casting Facility, Europe LPDC Die Casting Facility, Europe

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Casting The FutureIllichmann Integration with alicon group

• 70 years of proven track record.

• Magma & Pro-Cast Soft Casting

Simulation.

• Specialty in Handling Low Volume

Intricate Castings.

• 41 years of proven track record

for cost competitiveness learning's

from Indian Market.

• One of the Largest Foundry in India which

offers frugal engineering solutions

• Pioneer Users of Pro-Cast & Magma in India.

• Capabilities of Handling both low and High

Volume.

• To serve the customer with low &

high volume parts from Europe &

India locations.

• De-risking customers from

currency fluctuation.

•Providing the better options by

using strengths & ability of both

the organization.

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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 productThin Wall Casting 1.8mm

CAD system

Pro-Engineer Wildfire 2

Interface for Step Iges VDA and others

Tool design Magma casting simulation

Technology and methods at Illichmann

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 MgAl 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

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Casting The Future

PROCESS WORK SAMPLES

Rapid Prototyping Capabilities - Object Modelling by Synthetic Resin Technique

3D MODEL RPT MACHINE

RESIN OBJECT FORMED AS PER INPUT 3D GEOMETRY FINAL PROTOTYPE

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Casting The Future

PROCESS WORK SAMPLES

Rapid Prototyping Capabilities – Object Modelling by Laminated Paper Technique

3D MODEL RPT MACHINE

LAMINATED PAPER MODEL FORMED AS PER INPUT 3D DATAFINAL PROTOTYPE

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Casting The FutureSand casting technology at Illichmann

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Casting The FutureDesigning of the mold – Thin wall casting 1.8mm

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Casting The FutureSand core Facility

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Casting The Future

Changed to LPDC after

PROCAST

Analysis to Increase Productivity &

Eliminate Defects

Converter Housing for AVTEC Ltd.

(Apx. Wt-17.5 Kg)

Initial Casting was in GDC

Casting Simulation for LPDC process

using PROCAST

Engineering Capabilities, India

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Casting The Future

CAD

AutoCAD

Catia V5 R17

UG NX-4/5

Pro – Engineer Wild

Fire 2/3

Solid 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

3D Modeling based Design survive capable of designing from concept through Specification, tool design & validation.

Build to Print Capabilities, India

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Casting The FutureTool Room Facilities, India

CURRENTLY MANUFACTURING 20 DIES PER

MONTH

EQUIPPED WITH FULL FLEDGED SET UP

CONSISTING OF SOPHISTICATED

CNC

VMC

EDM

MILLING

LATHE

DRILLLING

SURFACE GRINDING

CMM

BY 2012 WILL BE MANUFACTURING 30 DIES PER

MONTH

PLANNING TO ADD FARRO ARM 3D SCANNING

FULL FLEDGED NPD CELL

TESTING FACILITY – BENCHFLOW

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Casting The Future

Spectrometer CMM Profile Projector

Millipore Testing Contour Measure Microscope Hardness Tester

Farro Arm

QA Equipments, India

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Casting The Future

Hot Tensile Testing Sieve Shaker Muffle Furnace

Core Gas Determination Bending Strength Testing

Scratch Hardness Tester

QA Equipments, India

X-Ray Salt Spray Testing

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Casting The FutureProduct Gallery – India

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Casting The Future

Engine Mounting Brackets EGR Valve

Product Gallery, India

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Casting The Future

CAC TanksRack Housing

Intake Manifold


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Casting The FutureProduct Gallery, India

Non-Automotive Components

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Casting The Future

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Product Gallery ,India

Power & Energy Sector products in India


Casting The Future

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Product Gallery , India

Medical sector products in India


Casting The Future

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Product Gallery , India

Defense sector customer in India


Casting The Future

Cylinder Heads Cylinder Heads for Motor Cycle

Cylinder Heads for Racing bikesPassenger Car


Cylinder Heads for Commercial Vehicles

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Casting The FutureProduct Gallery, Europe - (Illichmann Castalloy)

Tier 14W - OEM

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Casting The FutureProduct Gallery – Europe

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Casting The Future

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

Product Gallery Product Gallery – Europe

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Vaccum pump components for Automotive sector

Quantity : 5,000 pieces per annum

Process : Gravity Die Casting

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Swing Arm for BMW K72 Series | Weight : 5.6 kg | Quantity : 10,000 p.a | Low Pressure Die Casting

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Casting The Future

Cylinderhead

Weight: 0,7 kg

Quantity/Annum : 25,500

Gravity die casting

Cylinder

Weight: 2,5 kg


Gravity die casting

Swing Arm

Weight: 4.8 kg


Gravity die casting

Product Gallery – Europe

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Casting The Future

Wheel Hub

Weight: 1.07 kg


Low Pressure die casting

Carrier Foot Rest

weight: 0.35 kg


Gravitiy die casting

Water Pump Housing

Weight: 0.150 kg


Gravity die casting


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Casting The Future

Pulleys for Aerial Trams and Ropeways

7.9 kg | 11.9 kg | 19.8 kg

LPDC


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Casting The Future

Ski and Sea Doos

Aero Engines


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Diffuser

Weight: 1,6 kg

Gravity die casting

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http://www.zfsachs.com/


Casting The Future

Housing

Weight: 4 kg

GDC

Housing

Weight: 4.2 kg

GDC


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Casting The FutureEngineering Center Infrastucture

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Casting The Future

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2 3

6

TOOL DESIGN FEA & CFD FOUNDRY SIMULATION

REVERSE ENGINEERING3D CAD MODELLING CAD DRAFTING

1

CAD CONVERSION

4

8

TECHNICAL MANUALS

Engineering Services Portfolio – Silicon Meadows Engineering Services

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Casting The Future

CASTING EXTRUSION FORGING MOULDING

DIE CASTING –GDC, LPDC

DIE CASTING -HPDC

SAND CASTINGS

INVESTMENT CASTING –LOST WAX, LOST FOAM

CASTING DIES

EXTRUSION DIE DESIGN

SOLID PROFILES

HOLLOW PROFILES

FORGING DIE DESIGN

HOT FORGING

COLD FORGING

CASTING SIMULATION USING

PROCAST & MAGMASOFT

EXTRUSION SIMULATION

USING HYPEREXTRUDE

FORGING SIMULATION

USING FORGE2009

MOLDING SIMULATION

USING MOLDFLOW

COST EFFECTIVE TOOL MODIFICATION & TOOL MANUFACTURING FROM INDIA

PLASTIC MOLD DESIGN

INJECTION

VACUUM

BLOW

COMPRESSION

FOUNDRY SIMULATION SERVICES

TOOL MANUFACTURING SERVICES

TOOL & DIE DESIGN SERVICES

Engineering Services Portfolio – Silicon Meadows Engineering Services

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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

Engineering Services - Work Samples

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Casting The FutureEngineering Services - Work Samples

Big Quarter Ramp Big Quarter RampCad Model of Quarter Ramp

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Casting The FutureA single point of contact for engineering solutions

STRENGTH

•One of the biggest foundry infrastructure

in India.

•Ability to handle both low & high volume

•Total solution for AL casting under one roof

CORE BUSINESS

•Design Engineering

•Casting of Aluminum Component

COMMITMENT

•Provide value added solution through

Knowledge sharing between group companies

FOOT PRINTS

•Largest footprint in India & having presence

in Europe & USA.

Concept of

alicon group

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Casting The Future

STRATEGIC

INTEGRATION

STRONG

CUSTOMER

SUPPORT TECHNOLOGY EMPLOYEE

DEVELOPMENT

alicon group

believes that it’s

core strength is in

the people and

continues to invest

in the development

of its human capital.

alicon group focuses on producing exceptional and innovative aluminum castings, To consistently achieve this the group

has strategically integrated its PQCDDME with international technology, strong customer support and employee

development plans.

alicon group is

committed to strong

customer support and

takes advantage of

time zones to provide

24X7 support to its

global clientele.

Strong Inhouse

Design & Tool Room

facilities & Technical

JV with world leaders

Focus on Productivity,

Quality, Cost, Delivery,

Development, Morale &

Environment

(PQCDDME) with full

focus on continuous

improvement

Why alicon group

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Casting The FutureContacts

Europe Contact :

Mr. Andreas HeimKey Account Manager - Sales

E-mail: [email protected]

Mobile No:+43 664 849 1158.

Web site:- www.illichmann.com

Mr. Rajeev SikandGroup CEO

E-mail: [email protected]

Mobile No: +91-989 056 0099

Web site:- www.alicongroup.co.in

India Contact :

Mr. Shekhar DravidVP- Business Development

Email : [email protected]

Mobile No: +91- 9860794387

Web site:- www.alicongroup.co.in

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Europe Contact :

Mr. Frank PrangeManaging Director - Illichmann

Email : [email protected]

Mobile No: +43 664886 59621

Web site:- www.illichmann.com

http://www.illichmann.com/

http://www.alicongroup.co.in/

http://www.alicongroup.co.in/

http://www.illichmann.com/

· pdf fileprocast analysis to increase ... hpdc sand castings investment casting ... 2012 ...

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