Aluminium Die Casting

Expertise Into All Casting Processes

Overview

Rockman Industries has been into Aluminium Die Casting since the last two decades andis one of the few manufacturers equipped to follow the three types of die casting processes. Quality management, safety protocols and focus on environmental sustainability is the core of our manufacturing.

The outcome
  • High quality, complex die cast components catering to two-wheelers, four-wheelers, and other automotive/non-automotive parts.
  • Total employee involvement under the common platforms of TPM, GreenCo, quality circle, Kaizen, 5S, etc.
3
Casting Processes - HPDC, LPDC, and GDC
7
State of The Art Manufacturing Facilities - Ludhiana, Haridwar, Bawal, Mangli, Chennai, Halol, and Tirupati
300
CNC/VMC

Facilities

  • India’s first hot metal transfer from alloying unit to shop floor
  • Annual processing capacity of 45,000 tons of aluminium casting
  • Casting components as heavy as 6.5 kg
  • Daily production of over 1,80,000 components
  • Over 107 HPDC machines from 250T-1250T, expanding 1650/1800T
  • Processing more than 12 types of alloys
  • In house core manufacturing
  • Annual processing capacity of 10,000 tons of aluminium casting
  • Over 27 LPDC machines
  • Daily production of over 27,000 components.
  • In-house facility for T6 Heat Treatment
  • Porosity inspection using state-of-the-art X-Ray
  • Inspection with 3D CT capabilities
  • Integrated manufacturing facility for GDC parts
  • Over 148 GDC machines
  • Annual processing capacity of 50,000 tons of aluminium casting
  • Over 300 CNCs, VMCs, HMCs, SPMs, etc.
  • Special purpose machines for large production
  • Machining critical components for automotive transmission, engine, chassis, and other applications
  • In-line leak testing and ultrasonic washing
  • An environment-friendly integrated paint facility
  • Chrome-free pre-treatment system
  • Fully automated robotic paint shop
  • Liquid Painting using Electrostatic Guns
  • No manual handling from pre-treatment to finish
  • Manage multi colour without line stoppage/line loss
  • Zero-discharge Paint Shop
  • Facility for Heat Resistance painting
  • A robust supplier base for sheet metal parts
  • Forgings, springs, sintered products, seals, plastic parts, bearings, friction materials
  • Expertise in supplying full assemblies and modules to customers
  • Producing over 90,000 assemblies daily including high-critical and safety-related applications like brake drum assembly, wheel hub assembly

Facilities

High Pressure Die Casting

  • India’s first hot metal transfer from alloying unit to shop floor
  • Annual processing capacity of 45,000 tons of aluminium casting
  • Casting components as heavy as 6.5 kg
  • Daily production of over 1,80,000 components
  • Over 107 HPDC machines from 250T-1250T, expanding 1650/1800T
  • Processing more than 12 types of alloys

Low Pressure Die Casting

  • In house core manufacturing
  • Annual processing capacity of 10,000 tons of aluminium casting
  • Over 27 LPDC machines
  • Daily production of over 27,000 components.
  • In-house facility for T6 Heat Treatment
  • Porosity inspection using state-of-the-art X-Ray
  • Inspection with 3D CT capabilities

Gravity Die Casting

  • Integrated manufacturing facility for GDC parts
  • Over 148 GDC machines
  • Annual processing capacity of 50,000 tons of aluminium casting

Precision Machining

  • Over 300 CNCs, VMCs, HMCs, SPMs, etc.
  • Special purpose machines for large production
  • Machining critical components for automotive transmission, engine, chassis, and other applications
  • In-line leak testing and ultrasonic washing

Surface Treatment

  • An environment-friendly integrated paint facility
  • Chrome-free pre-treatment system
  • Fully automated robotic paint shop
  • Liquid Painting using Electrostatic Guns
  • No manual handling from pre-treatment to finish
  • Manage multi colour without line stoppage/line loss
  • Zero-discharge Paint Shop
  • Facility for Heat Resistance painting

Assemblies & Modules

  • A robust supplier base for sheet metal parts
  • Forgings, springs, sintered products, seals, plastic parts, bearings, friction materials
  • Expertise in supplying full assemblies and modules to customers
  • Producing over 90,000 assemblies daily including high-critical and safety-related applications like brake drum assembly, wheel hub assembly

Products

Automotive Components

Pan Upper Oil

Cover Cylinder Head

Cover Cylinder Head

Fuel Rail Assembly

Passage Water Assembly

Chain Tensioner Housings

Tensioner Rails

ECU Housings & Covers

Fuel Pump Housing

Housing

Engine Mounting

Fan Body

Engine Mounting

Valve Body

Throttle Body

Main Housing

Differential Cover Housing

Transmission Housings

EPS motor housing

Locking Bracket Assembly

Bearing Segment

Cover for Shift

Servo Housings

Fixing Bracket

Gear Shift Fork

Modulator Valve Body

Viscous Clutch Disc

Viscous Clutch Cover

Viscous Clutch Case

Mounting Bracket

VOP Cover and Deckel

Water Pump HSG

Vaccum Pump HSG

Oil Pump HSG

Oil Pump Cover

Flange HSG

Vaccum Pump HSG

HSG for Graziano

Air Drier Body

Shift Fork Assemblies

Two Wheeler components

Scooter Alloy wheel

Motorcycle Alloy Wheel

Crank Case

Crank Case Cover

Cylinder head

Bottom Case

Two Wheeler Assemblies

Two Wheeler Assemblies

Two Wheeler Assemblies

Scooter Crank Cases

Products

Pan Upper Oil

Cover Cylinder Head

Cover Cylinder Head

Fuel Rail Assembly

Passage Water Assembly

Chain Tensioner Housings

Tensioner Rails

ECU Housings & Covers

Fuel Pump Housing

Housing

Engine Mounting

Fan Body

Engine Mounting

Valve Body

Throttle Body

Main Housing

Differential Cover Housing

Transmission Housings

EPS Motor Housing

Locking Bracket Assembly

Bearing Segment

Cover for Shift

Servo Housings

Fixing Bracket

Gear Shift Fork

Modulator Valve Body

Viscous Clutch Disc

Viscous Clutch Cover

Viscous Clutch Case

Mounting Bracket

VOP Cover and Deckel

Water Pump HSG

Vaccum Pump HSG

Oil Pump HSG

Oil Pump Cover

Flange HSG

Vaccum Pump HSG

HSG for Graziano

Air Drier Body

Shift Fork Assemblies

Scooter Alloy wheel

Motorcycle Alloy Wheel

Crank Case

Crank Case Cover

Cylinder head

Bottom Case

Two Wheeler Assemblies

Two Wheeler Assemblies

Two Wheeler Assemblies

Scooter Crank Cases

Engineering & Designs

Project Management

Project management serves an important goal in delivering the product at the right time and location. The key to customer delight is the timely execution of projects.

Rockman manufactures all in-house tools and has expertise in designing precision tools.

The Cross-Functional Team takes care of Project Management. The process takes place by defining the project goals & targets. Later it is completed at the time of final PSW Submission. Close interaction is maintained with the customer during the project development.

Process Development ensures timely identification and deployment of all the necessary resources. Project deployment is processed in terms of inspection, manpower, utilities etc. The process ensures smooth development, trial, inspection and submission of PPAP as per as timelines.

Tool Design & development

  • In house centralised die design and development center in Bawal
  • Producing 150+ dies/ year at Ludhiana & Haridwar facilities
  • Capability to produce tools upto a weight of 5 tonnes
  • High precision CNC, EDM, wire cut and high speed machines for machining of tool and dies
  • Spotting press for die matching
  • End of life drawing and document management done through dedicated windchill based PLM system