Our Process

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Process Capability

With the technology developed and refined over a period of time, the company is able to produce castings with very close tolerance and surface finish to international standards.

The achievable tolerances for parts produced through investment casting are established in an international norm: VDG P690. TCL produces castings according to this norm.

The tolerances specified below can be used as an indication, depending on the alloy and the part geometry

General linear tolerances (in mm) according to VDG P690 D1

0-6 ± 0.150
>6-10 ±0.180
>10-18 ± 0.220
>18-30 ±0.260
>30-50 ±0.400
>50-80 ±0.450
>80-120 ±0.550
>>120-180 ±0.800
>180-250 ±1.200
>250-315 ±1.300
>315-400 ±1.800
>400-500 ±2.000

General form and position tolerances (in mm) according to VDG P690 D1

Nominal Dimension Range For Straightness / Flatness (mm) Roundness Parallelism/ Symmetry Coaxiallity
0-6 0.15 0.20 0.25 0.30
>6-10 0.18 0.25 0.30 0.35
>10-18 0.25 0.40 0.40 0.50
>18-30 0.30 0.50 0.50 0.60
>30-50 0.40 0.60 0.70 0.80
>50-80 0.60 0.80 1.00 1.10
>80-120 0.80 1.00 1.30 1.30
>120-180 1.10 1.30 1.80 1.80
>180-250 1.50 1.80 2.50 2.40
>250-315 1.90 2.30 3.15 3.00
>315-400 2.40 2.90 3.80 3.80
>400-500 3.0 3.40 4.40 4.40

As cast tolerance of angels depends on their location in the casting. They range from ±0.5° for well supported positions to ±2° where inherent distortion could be expected. Inclusion of gussets and ribs often minimizes distortion and many sections can be mechanically straightened.

Blind hole can be cast if length does not exceed the diameter.

Average Ra value generally ranges between 4.5 – 6.3 Ra.

From concept to finished drawing, TCL’s engineers are ready to assist customers at all stages of casting design. They can provide suggestions and guidance regarding \ tolerances and design details, alloy selection and even approximate pricing. Their aim is to help customers select the best manufacturing process, whether or not it is investment casting.

It is essential to ensure that all the details required to make an accurate feasibility study and cost estimation are specified.

The below list can be used as a guide for the information we require to prepare an accurate feasibility study and cost estimation:

  • 2D Drawing
  • Material Specification
  • Heat treatment condition / Mechanical Properties
  • Annual Quantity Requirement
  • Part Weight
  • 3D Model
  • Application / Industry Sector
Steel Investment Castings/High Alloy Steel Investment Castings / Aluminum Investment Castings

TCL pours over 150 different alloys according to internationally accepted standards such as ASTM, DIN, JIS, IS and BS.

Our broad selection of alloys allow us to cater several industry sectors and meet their performance requirements.

MATERIAL SPECIFICATIONS

  • CARBON STEEL
  • ALLOY STEEL
  • STAINLESS STEEL
  • MARTENSITIC STAINLESS STEEL
  • AUSTENITIC STAINLESS STEEL
  • DUPLEX/SUPER DUPLEX STAINLESS STEEL
  • PRECIPITATION HARDENING STEEL
  • CAST IRON
  • SG IRON (400 WITH 15% ELONGATION)
  • PHOSPHOROUS BRONZE
  • BRASS
  • ALUMINIUM ALLOY
  • COPPER ALLOY

Research & Development

Our approach to research and development is focused toward continuous improvement.

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Continuous Process Improvement

Continuous process improvement is an objective to be achieved at all levels in the company, this is ensured through process study and evaluation in order to optimise parameters and encompass all the processes.

New product development

The company attaches great importance to new product development in new industry segments, we understand the value of expanding our capabilities with new material specifications, weights and complexity.
Considerable time and money is saved by providing 3D printed prototype parts offered by us.

What are Industry 4.0 Manufacturing Principles?

We at TCL, we believe that everything begins with measurement.

As a part of industry 4.0, we have installed world class IOT, AI and Surveillance setup for monitoring and controlling facilities at our works and continue to improve the technology on an ongoing basis. Our surveillance monitoring and control system keeps continuous track of machines and to control required parameters which gives us access to the real-time data, which can ultimately boost the efficiency and helps us to make smarter and faster decisions of our entire operation. To implement the industry 4.0, enables us to manage our production, process and efficiency at optimum levels.

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