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COMPANY PROFILE

• We Would like to Introduce our Company as one of the Pioneer

Company in India having Specialization in Manufacturing of various

Types of closed Die forging.

• We are ISO 9001-2008 Certified & Approved by TUV Rhineland. We

Manufacture Quality Forging ( Hot Forging ) as per customer

specification & Samples.

• Our main product line includes closed die forging for Automobile

Industry, Agricultural Implements, MS Flanges, Stainless Steel

Flanges, Forge Fittings, Railway gears, Pinion, Engine Cover etc.

We also supply Customized Forging as per buyer’s Drawings /

samples.

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• Our scope of Forging from 0.5 to 750 Kilograms of a single piece.

• The Company produces 95% of its Products for usage in Petroleum

and Gas/Oil Sector Industries and 5% for usage in other Industries

and 90% of its Products are exported to Global Customers with

majority share in USA, CANADA, EUROPE & GULF.

• We are also preparing for TS-16949.

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RAW MATERIAL SUPPLIER

• Kalyani Carpenter Special Steels Pvt. Ltd.

• Mahindra Sanyo Special Steel Pvt. Ltd

• Harison

• Rashmi Steel

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LIST OF CERTIFICATE

• ISO 9001 – 2008

• PED

• TSE

• Candian Registration For All provinces

• Kuwait Oil Company

• Petrobras

• EIL

• NPCIL

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MANUFACTURING PROCESS

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DESIGNING OPTIMISED PROCESS FOR MANUFACTURING FORGED PART.

CREATION OF FORGING PART DRAWING AND 3D MODEL FROM CUSTOMERS MACHINING DRAWING AND 3D MODEL.

CREATION OF DRAWINGS AND 3D MODELS OF ALL THE TOOLING, REQUIRED FOR MANUFACTURING FORGED PARTS.

3D MACHINED MODEL 3D FORGING MODEL

FINISHER TOP

FINISHER BOTTOM

BLOCKER TOP

BLOCKER BOTTOM

DESIGN CAPABILITIES

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GENERATING PROGRAMS FOR MANUFACTURING DIES AND TOOLS.

IN ORDER TO PROVIDE COMPLETE SOLUTION TO CUSTOMER,WE CAN PROVIDE VALUE ADDITION SERVICES LIKE:-

DESIGN OF CHECKING FIXTURES, TEMPLATES etc.

DOCUMENTATION PREPARATION LIKE

1.CONTROL PLAN

2.PFMEA

3.PPAP

4.APQP

5.WORK INSTRUCTION etc.

CUSTOMER STANDARDS REVIEW.

DESIGN CAPABILITIES

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VIRTUAL MANUFACTURING:-

SIMULATING EACH STEP OF FORGING PROCESS TO CHECK

1.FILL-UP,

2.AVOID DEFECTS,

3.PREDICT LOAD AND ENERGY,

4.NUMBER OF BLOWS (IN CASE OF HAMMER),

5.DIE STRESS

6.GRAIN FLOW.

UPSET BLOCKER FINISHER TRIMMED PART

INITIAL STOCK

1.START TO END PROCESS SIMULATION

BLOCKER

FINISHER

DESIGN CAPABILITIES

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2.PREDICTION OF FORGING DEFECTS

FOLDS INSIDE THE PART

ACTUAL FOLDS OBSERVED

FOLDS OBSERVED IN SIMULATION

DESIGN CAPABILITIES

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HIGH STRESS AREA

AT ROOT IN FINISHER

DIE

CRACK IN ROOT AREA

EXTENDING TILL LAND IN

THE DIE

ACTUAL DIE CRACKS

SIMULATED DIE STRESS FOR FINISHER BOTTOM DIE

HIGH STRESS AREA

AT OIL SLOTS IN

FINISHER DIE

CRACKS OBSERVED

AT OIL SLOTS AREA

3.DIE STRESS ANALYSIS

DESIGN CAPABILITIES

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RAILWAY WHEEL

SIMULATED GRAIN FLOW

3.GRAIN FLOW

DESIGN CAPABILITIES

PINION SHAFT SIMULATED

GRAIN FLOW

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LIST OF MATERIAL USED

• Carbon and Alloy Steel ( 17CrNiMo6, 15Ni7Cr4Mo2, 8822H, SAE-

1020, A105, SAE-4140, A86 B45.)

• Stainless Steel ( 304L, 316L, 1.4541, 1.4571)

• Nickel Alloy ( A-20, A-400, C-276 )

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EQUIPMENT LIST

• Russian Hammer - 16 Ton

• Belt Drop Hammer - 2 & 3 Ton

• Forging Press - 2000 Ton

• Trimming press - 1600 Ton, 200 Ton, 500 Ton

• Billet Heating Furnaces - 2 Box, 2 Pusher Furnaces

• Induction Heater - 400 KW

• Band Saw Machine - 15 Nos.

• Compressor - 15 Nos.

• Lathe Machine - 6 Nos.

• Fork lift - 02 No.

FORGE SHOP

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EQUIPMENT LIST

• VMC - 02 Nos.

• Lathe Machine - 01 No.

• Drilling Machine - 01 No.

• Compressor - 01 No.

• Shaping Machine - 01 No.

• Pneumatic Grinder - 02 Nos.

• Welding Machine - 03 Nos.

DIE SHOP & TOOL ROOM

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EQUIPMENT LIST

• VTL Machine - 08 Nos.

• CNC Machine - 35 Nos.

• VMC Machine - 03 Nos.

• Drilling Machine - 03 Nos.

• Punching Machine - 02 Nos.

• Lathe Machine - 05 Nos.

• Fork Lift - 02 Nos.

VTL & CNC SHOP

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EQUIPMENT LIST

• Normalising Furnace (2 Ton) - 02 Nos.

• Tempering Furnaces (2 Ton) - 02 Nos.

• Water Quenching Tank - 01 No.

• Oil Quenching Tank - 01 No.

• Charger ( 2 Ton) - 01 No.

• Fork Lift - 01 no.

• Shot Blasting Machine - 02 Nos.

• Lathe - 03 Nos.

• Band Saw - 01 No.

• Muffle Furnace - 01 No.

HEAT TREATMENT

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EQUIPMENT LIST

• Spectrometer

• Microscope

• UTM ( Universal Testing machine)

• LPT (Liquid Penetrant Test)

• PMI Analyzer

• Radiation Testing Meter

• Magnetic / Ultrasonic Crack Detection

• Pyrometer

• Brinell Hardness Tester

• Dial Gauge, Micrometer & Vernier etc.

TESTING & INSPECTION

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CRANK SHAFT

CONNECTING RODS

PRODUCT PORTFOLIO

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GEARS

CAM SHAFT

DIFFERENTIAL CASE

INPUT SHAFT

PINION

PRODUCT PORTFOLIO

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RAILWAY WHEEL

RAILWAY ENGINE COVER

PRODUCT PORTFOLIO

TOP DECK CENTRE

(SIMULATION RESULT)

SIMULATION RESULT

TOP DECK CENTRE

(ACTUAL RESULT)

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OUR CUSTOMERS

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CONTACT ADDRESS

Registered & Corporate Office

Address: 701, Palmspring, Palmcourt Complex,

Link Road, Malad – West, Mumbai – 400064

Tel: 022 4042 6565

Fax: 022 4042 6566

E-mail: info@hiltonmetal.com, sales@hiltonmetal.com

Factory

Address: Shah & Mehta Ind.Estate, Village Ghonsai,

Tal. Wada, Dist. Thane, Maharashtra, India

Tel: 91-2526-307 900

Fax: 91-2526-307 901