Process

Since its inception in 2009, Kalaria Auto Forge Pvt Ltd has been a leader in manufacturing precision forgings, adhering to IS:3469 Part-I-II-III 1974 normal tolerance standards. Driven by a burning ambition and core values, we specialize in producing precision forgings, machined components, and sub-assembled products for global customers. Our facilities include close die drop forging, heat treatment with oil and water quenching, and precision machining to meet exact customer specifications.

The organization has evolved into an innovative, customer-oriented, and robust entity, renowned for high-quality carbon and alloy steel forged and machined components. We collaborate with our customers to provide comprehensive engineering, design, and development services.

Kalaria Auto Forge Pvt Ltd delivers “first-time-right” products using Near Net Shape technology and a Lean Product Development approach. Our progressive and innovative engineering team embraces challenges in new product development, striving for the highest quality, lowest cost, and shortest development lead times.

We produce complex, critical profile forgings with high accuracy thanks to our in-house die designing process, which utilizes the latest VMC technology. This advanced quality control allows us to manufacture dies and tooling with exceptional precision.

Our in-house machining facility, equipped with high-end CNCs and VMCs, enables us to establish dedicated machining lines. These lines, featuring advanced CNCs and VMCs, serve industry leaders across various segments.

Design & Development

Our design capabilities include:

• 2D drafting with AutoCAD
• 3D solid modeling with Unigraphics NX
• VMC programming with Unigraphics

Die Manufacturing

Our in-house die and tool manufacturing capability, supported by Unigraphics NX CAM/CAD, enables us to respond rapidly and accurately to our customers' complex geometric requirements. The entire facility is interfaced with the CAD-CAM center via a fiber-optic network, ensuring high-quality tools and dies with exceptional consistency and repeatability.

We conduct Value Analysis to deliver exceptional quality and the best value to our customers from the outset. Our tool design philosophy focuses on ensuring a stable process to enhance quality.

Forging

Production Facilities – Closed Die Forging, Upset Forging:

• Materials: Carbon and Alloy Steel, Stainless Steel
• Standards: DIN, ANSI, EN, ASTM, JIS, etc.
• Belt Drop Hammers: 1 Ton (Qty: 2), 1.5 Tons (Qty: 1), 2.0 Tons (Qty: 1)
• Design Cell: Utilizing CAD/CAM facilities
• Production Capacity: 700 MT/Month
• Manufacturing Range: 0.5 kg to 30 kg
• Induction Heaters: For forging
• In-House Production: Forging tools and dies produced by VMCs

Heat Treatment

Kalaria Auto Forge Pvt Ltd expert in heat treatment, ensuring outstanding performance of our products in high-pressure and safety-critical applications. Our heat treatment furnaces minimize internal stresses, refine grain structure, and enhance mechanical and physical properties of our products.

Our Heat Treatment Plant provides the following services:

• Normalizing
• Iso-annealing
• Spheroidize annealing
• Hardening and tempering
• Quenching (oil/water) and tempering
• Shot blasting

Precision Machining

Kalaria Auto Forge Pvt Ltd provides in-house machining facilities for diverse product lines, allowing us to deliver products in either pre-machined or fully machined condition, ready for installation with superior quality. Our state-of-the-art CNCs/VMCs and unwavering focus on quality and timely delivery enable us to meet rigorous customer requirements consistently.

Our precision machining facility is equipped with technology capable of manufacturing both conventional and complex geometries. We have dedicated machining lines set up to cater to renowned industry names across various segments.

Testing and Inspection

Kalaria Auto Forge Pvt Ltd boasts state-of-the-art laboratories providing metallurgical and metrological testing capabilities for raw materials, in-process, and finished components. Our team comprises certified experts with up-to-date knowledge of the latest technologies and best practices, ensuring the delivery of quality products and excellent after-sales service to our customers.

The following tests are conducted:

• Hardness tests (Brinell, Rockwell)
• Mechanical properties testing (Tensile, Impact)
• Physical testing (acid pickling, internal soundness, inclusion, micro-testing, grain size)
• Chemical composition analysis using spectrometers
• Grain flow assessment
• Carburization examination
• Surface bend evaluation
• Inclusion inspection
• Magnaflux for crack detection
• Microscope with camera and image analyser

Logistics

Kalaria Auto Forge Pvt Ltd consistently ranks among the top in customer satisfaction, irrespective of geographical location. We are committed to delivering products and services within agreed lead times, ensuring our customers receive top-quality products and exceptional service. From freight transportation to warehousing and distribution, we handle every aspect to delight our customers.

In order to enhance our geographic reach and offer superior services to our valued customers, we prioritize providing the following value-added services:

• Door-to-door delivery
• Just-in-time delivery
• Early engagement with customers for new developments