Infrastructure

Die Design & Manufacturing
Happy Forgings Limited have various CAD/CAM packages like Uni-Graphics, Solid Works, Work NC, Vera cad, etc. These packages help us in reducing manufacturing lead times and repeatability when we re-cut the dies.

3D Simulation : Happy Forgings Limited have Deform â�� 3D from USA and Forge â�� 2009 From France. With our 3D simulation facility we develop the parts offline and hence optimize the forging process to have better utilization of the forging equipment and material. This further helps in improving utilization of forging equipment and ultimately results in reducing engineering and financial risk.
Tool Manufacturing Facilities : HFL has latest Tool & Die manufacturing facilities consisting of Conventional Tool Room and CNC Tool Room with CNC Vertical Machining Centres by Makino, DMG, Okuma & TAL

Hot Forging Facilities

Capacity of Equipment	No. of Units	Weight Range (kg)	Typical Components
8,000 MT Press	1	40 – 115	Front Axle Beams, Crank shafts, Connecting rods, Knuckles, Diff. case, Crown wheels
4000 MT Press	1	5 – 25	Car & Tractor crank shafts, Knuckles, Connecting rods, Diff. case
6 MT Hammer	1	20 – 75	Crown wheels, Bull gears, Transmission shafts
3 MT Hammer	1	5 – 20	Pinions, shafts, Transmission gears
3.5 MT Hammer	1	5 – 20	Pinions, shafts, Transmission gears
2,5 MT Hammer	2	2 – 8	Transmission components, Levers
1.5 MT Hammer	1	2 – 5	Transmission components

6 Ton Pneumatic Hammer
- Part Range : Weight – 20 Kgs to 75 Kgs
- Equipped with 1600 KW induction billet heater
1.5 Ton, 2 Ton, 2.5 Ton, 3 Ton & 3.5 Ton Drop Hammers
- Part Range : Weight – 2 Kgs to 20 Kgs
- Equipped with 600 KW induction billet heater
8000 Ton Forging Press Line
- Part Range : Weight – 40 Kgs to 115 Kgs
- Installed with Fully Automated Reduce Roller.
- Installed with 4000 KW Billet Heater with 3 Way Accept Reject System.
- Installed with 4 Jet water de-scaling system.
- 1600 Ton & 1250 Ton Trimming Press
4000 Ton Forging Press Line
- Part Weight : 5 Kgs. To 25 Kgs.
- Installed with 1200 KW Billet Heater.
- 1000 Ton & 350 Ton Trimming Press.
- With 2 way Accept Reject System

Heat Treatment Facilities

Continuous Hardening & Tempering Quench type Furnace
- Capacity : 4 Ton / Hr
- Equipped with Instrumentation Panel for Temperature Controls & Recording with SCADA software with data logging & history recording.
- Two Quenching Tanks for Polymer & Water Quenching
2 Ton / Hr. Ultra – Modern Hardening & Tempering Furnace with Polymer quenching Facility
ISO Thermal Annealing Furnace
Normalizing Furnace
Controlled Cooling for micro alloys

Shot Blasting Facilities

DISA Shot Blasting Machine : Capacity of 5 Ton / Hr. Shot Blasting with Shot of S330 to S550 range.
THUMB Shot Blasting Machine : 5 Nos. THUMB Shot Blasting Machines having capacity of 500 kg per Batch Shot Blasting with Shot of S330 to S550 range.

Machining Facilities

General CNC Machining Line : Modernized Machine Shop for Blank Turning, Drilling & Tapping for Transmission Components (total 40 Nos. of CNC lathes, VMC, and VTLs of DMG, Makino, Daewoo & ACE)
3 CYL. Crankshaft Finishing Line : Highly flexible 3 cylinder Crank Shaft Machining Line capable of manufacturing 10,000 - 12,000 crankshafts per month Upto 650mm length.
4 CYL. Crankshaft Finishing Line : Highly flexible 4 cylinder Crank Shaft Machining Line capable of manufacturing 10,000 - 12,000 crankshafts per month Upto 650mm length
6 CYL. Crankshaft Finishing Line : Highly flexible 6 cylinder Crank Shaft Machining Line capable of manufacturing 2500 – 3000 crankshafts per month Up to 1250 mm length.
Front Axle Beam Finishing Line : Front Axle Beam is machined in single set up with Touch Probe System for equal wall thickness of King Pin Bosses (Self aligned)
Steering Knuckle Fully Finish Line :
- DMH - 500 HMC’s
- Daewoo Turning Centres
- Micromatic Angular Grinding Machine
- IEI Induction Hardening

Metallurgical Quality Control

For testing the quality of Incoming Material and to ensure that the Forged Output is having the desired quality of the customers, hfl has independent Metallurgical Lab with the following infrastructure :

24 Channel Optical Emission Spectrometer Magellan
Quantron GmbH-German made
2 special CHANNELS for each nitrogen & oxygen)
Mobile Spectrometer (Spectro Analytical Instrument -German Make)
Image Analyzer Software and microscope or microstructure analysis
MPI equipment 3 phase DC current as per STM E1444 to check modes
Auto combination shot to check LONGITUDINAL & transverse CRACKS in single shot.
Tensile Testing System capable of measuring tensile strength, yield strength, % elongation & modulus of elasticity with graphical output
Ultrasonic Meta scope for detection of internal cracks in steels bars
Impact Testing Facility
Rockwell, Brinell & Vickers Hardness Testing Machines

Eddy Current Testing System :
- Eddy Current Testing System capable of segregating for following parameters :
  - Electrical Conductivity
  - Magnetic Permeability
  - Grain Size
  - Specimen Shape
  - Specimen Size
  - Micro-Structure
  - Hardness
  - Heat Treatment Condition
  - Alloy Type
  - Tensile Strength

Dimensional Quality Control

For testing the quality of Machined Parts and to ensure fulfillment of drawing requirements, hfl has independent Standard Room with the following infrastructure :

Mitutoyo - Japan make Profile Projector model 3105
Mitutoyo - Japan make Surface Roughness Tester SJ400
Mitutoyo Japan make Contracer model CV-3100H
Coordinate Measuring Machine model Beyond Crysta C7106 with PH-10m motorized Head
Trimos Master Height Gauge
Adcole Cylindrical Coordinate Measuring Machine for crank shafts