Engineering

Design

Design is the core of high precision stamping, cutting, and tool forming. Our advanced design centre is equipped with the latest designing software.

Our experienced designing personnel always focus on the customer’s specific needs while identifying not only the potential cost-saving opportunities but also suggesting favourable alternative materials to optimise the geometry of the customer’s parts. In most cases we optimise designs for manufacturing by making use of 3D modelling techniques, lowering manufacturing labor and material as well. The first and foremost goal of our design centre is to produce for our valued customers a product design that is superb on functionality and unbeatable on price.

Our Design Engineers Use:

  • CATIA V5, Solid Works, AutoCAD, and Uni-Graphics for Design
  • Pam Stamp, Hyper form and Auto Form-7 for simulation
  • Tebis and Work NC for CAM

Tool Room

A combination of conventional and ultra-modern machines is what defines our tool room. Here our engineers develop solutions which are transformed into highly efficient dies and forming tools. It enables us to deliver the right product at the right time and the right price. It’s our tool room where geometry, surface topology, and properties of the material being processed are determined.

Caparo has a major Tool Manufacturing Division, located at its own 120-acre industrial park located at Sunguvarchatram, Sriperumbudur Industrial Area, right on Chennai-Bengaluru Highway. The Tool Division is essentially engaged in the manufacture of Stamping Tools and Dies, mainly in Casting Housings, ranging from ~ 2MT to > 12MT in weight. These Dies are used for stamping out panels and other members in different grades of Steel and Aluminium alloys, mainly for body and chassis assemblies of Passenger Vehicles, Commercial Vehicles, Two-wheelers, and vehicles used in Agriculture supports and Earthmoving industry.

Apart from making Tools and Dies for operations in Group Units, the Tooling Division also manufactures Tools for external customers, as a commercial Tooling Division. As an integrated entity, it has all functions involving Forming Simulation, Tool Design, Manufacture (3D VMC and General Purpose), Assembly and Fitting, and Trials in its scope of operations. Here, the Design Services are manned by competent members operating on Simulation Software platforms like Auto Form and Pam Stamp, and Design Software platforms like Unigraphics, Catia V5, Solid Works, and AutoCAD. Blank Development is worked out through FTI (Forming), and machining interface carried out primarily by Tebis and Work NC.

The Unit has 9 Nos. of VMCs, the largest one being of 5 axes with a total travel of 5 m x 3 m. It is well supported by Conventional Machining Equipment. For assembly and trials, the Unit works on a 100T Die Spotting Press, and High Powered and Mid-High Powered Mechanical Presses.

For Quality Control and Inspection activities, the Unit has Coordinate Measuring Machines (Bridge Type and Portable Type), and Blue Light Surface Scanner, apart from conventional measuring instruments.

Over the years, the Tooling Division has developed many Tools and Dies for a large number of critical components having highly intricate profiles requiring high levels of surface accuracies. It has been well acclaimed for Tooling for deep drawn parts, heat shields made of very thin aluminum alloys, and Chassis Members (Long Members / Cross Members) for Commercial Vehicles. The Unit was amongst the earliest Tooling Units in India to develop Tools for parts in 440 MPa UTS and has since been widely engaged in the development of Stamping Tools for steels in higher tensile strength (590 MPa and above).

Caparo has also entered the Technical Alliance with the Shin Young Group, a famous Tool and Die Manufacturing Group based in Korea, with global outreach all across. This enables access to cutting-edge technology and process in the development of Tools and Dies as per global standards. The Tooling Division at Chennai is designated as the principal hub of this Alliance.

The Machining Infrastructure in the Tool Room includes:

  • Horizontal & Vertical Milling Machines
  • Vertical Milling Machines
  • Milling -Turret Type
  • Lathe
  • Tool & Cutter Grinder
  • Surface Grinder
  • Cylindrical Grinding
  • Pedestal grinder
  • Radial Drilling

Strengths in CAM, Simulation, and Design Area

We’re having in-house design and development centre with Simulation, Tool Design and CAM Program capacity with below mentioned set of the latest software:

  • For Design - CATIA V5, Solid Works, AutoCAD, and Uni-Graphics
  • For Simulation- Pam Stamp and Auto Form-7
  • For CAM- Tebis and Work NC.

Forthcoming Additions to the Tool Room are:

QC Equipment
  • Blue light Scanner -ATOS Compact Scan 8M
  • Mobile hardness tester – (2nd unit)
  • Digital Micro height
Machines
  • Conventional equipment, like plano milling
  • VMC
Functions
  • F&A team enhancement
  • Design team enhancement – Shin Young support
  • PPC and Machining enhancement
  • Onsite and offshore training by Shin Young