Manufacturing :

Manufacturing Process
Our manufacturing foundry is the home of traditional foundry and advanced centrifugal casting technologies. The cylinder liner production line is where you find the action: large furnaces, fiery heat, and sweaty hard-working foundry men working to melt metal chunks into lava-like fluids and hardening the fluid into the final product.

RAW MATERIAL
Cylinder liners are made from cast iron, which contains graphite making it suitable as a natural lubricant. Some of the alloying elements we mix are chromium, molybdenum, nickel, copper, phosphorus, Tin and silicon to improve its mechanical and chemical properties.

For decades, Prarthana has been an expert in the selection and acquisition of high-quality, wear-resistant raw materials. We have a strict material quality implementation that only selects materials with the right properties and wear-resistant element doping ratio.

The materials go through a series of metallurgy tests before the melting process to ensure we hit the most appropriate temperature and incubation time. This ensures that the casting is completed at one time without erroneous results.

Melting
Melting is at the beginning of the casting process. We take heed of the customers' requirements first before melting the metal chunks into the furnace. To meet the constant demands of various customers and brands around the world, we have two 300-kg induction furnaces and 500-kg induction furnaces used for our induction melting process.

In this step, pure metal is melted in the induction furnace and allowed to heat at very high temperatures to totally transform any metal pieces into liquid form in the crucible.

Pouring Next, the molten metal from the crucible is poured into a centrifugal die/cavity to get the right form. In our ferrous manufacturing grounds, we use a two-stage ladle transfer process to pour the liquid into the mold. One step involves a large ladle for pouring and the second stage involves industrial pouring based on the product weight.

In the pouring process, we standardize the metal alloy mixtures according to the formula specified by the client.

Certain alloying elements are also added with the proper percentages onto the treatment ladle prior to casting. For example, we can add grey iron, silicon, carbon, and other additives to cast iron to refine its surface, chemical composition and weight, and resistance to high temperature and pressure.

Centrifugal Casting
Centrifugal casting is the heart of our cylinder liner manufacturing process. At this step, the molten liquid having the right specifications is poured into a spinning mould that rotates at a high RPM. The constant spinning produces a centrifugal action forcing the metal into the inside wall of the die to produce a hollow cylindrical shape until it cools and solidifies. During the process, the impurities are left in the inside diameter of the tube, which will then be machined afterward.

Roughing boring
Rough boring is the process that comes right after the centrifugal casting step in which we remove any suspended metal or scrap metals and prepare the hole for finishing. In this process, we carefully perform the boring operations using semi-automated vertical boring machine. Our vertical boring machine are performing at high load capabilities for more precise dimensional accuracy, taper, surface finish, and ovality.

Fine Boring
Fine boring is the process where we perform a complete refinement of the bore that is produced during the rough boring process. This is where we machine the hole to achieve a close bore tolerance, centre axis positioning, and exceptional surface finish. Fine boring machining is performed with cutting depths below 0.5 mm.

Semi-finished CNC Turing
With a fully automated CNC machine, the cylinder sleeves are turned by piece to perform rough refinement of the outer diameter surface. These operations involve cutting the outer surface based on the material drawing specified by the clients.

Outer Diameter CNC Turing

With a fully automated CNC machine, we perform the outer diameter turning to further enhance the dimensional accuracies, geometrical parameters, and surface roughness of the grooves. We use a CNC turning machine to further eliminate inaccuracies that may not have been detected during the lathe machining process.

By this, all external diameters, end faces, and grooves are finished in a short manner of time meeting the product's size tolerance.

FINAL INSPECTION
Finally, our QC experts do a final inspection of the cylinder liners based on the standard drawings. This critical process is essential for the service life and reliability of the cylinder liners. Intricate, multi-stage inspection may reveal some non-compliant products which we need to send back to production or disregard from the finished product.

For this step, we do have complete tools for physical inspection of the cylinder liner structure, such as a digital Vernier calliper, digital micro meter, Go No Go Gauges, pneumatic plug gauge and ring gauge, and many more.

Laser Marking

We use laser marking equipment to mark/ identify the client's brand/logo/Part number on the surface of the cylinder liner along with our manufacturing identifications code. As a cylinder liner manufacturer, we also accept OEM requests from different brands around the world.

Packing
The packaging process involves cleaning the products with rust protection oil, packing securely to prevent rusting, and storing for Domestic and international Clients. Each batch of finished cylinder liner packages is loaded in pallets or corrugated boxes duly identified with labels.

Testing Equipment
Prarthana houses several testing equipments such as spectrometer, Brinell hardness tester, tensile testing machine, metallographic microscope, Digital Pyrometers, Smart Ferro Lab, and Sand testing equipments to test the cylinder liner samples. We ensure the liners are on the right hardness, chemical composition, metallographic structure, and strength before dispatching.