Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. The processes that have this common theme, controlled material removal, are today collectively known as subtractive manufacturing. Machining is a part of the manufacturing of metal products, but it can also be used on materials such as wood, plastic, ceramic, and composites.

There are many kinds of machining operations, each of which is capable of generating a certain part geometry and surface texture.

In turning, a cutting tool with a single cutting edge is used to remove material from a rotating workpiece to generate a cylindrical shape. The primary motion is provided by rotating the workpiece, and the feed motion is achieved by moving the cutting tool slowly in a direction parallel to the axis of rotation of the workpiece.

Drilling is used to create a round hole. It is accomplished by a rotating tool that typically has two or four helical cutting edges. The tool is fed in a direction parallel to its axis of rotation into the workpiece to form the round hole.

In boring, a tool with a single bent pointed tip is advanced into a roughly made hole in a spinning workpiece to slightly enlarge the hole and improve its accuracy. It is a fine finishing operation used in the final stages of product manufacturing.

Reaming is one of the sizing operations that removes a small amount of metal from a hole already drilled.

In milling, a rotating tool with multiple cutting edges is moved slowly relative to the material to generate a plane or straight surface. The direction of the feed motion is perpendicular to the tool’s axis of rotation. The speed motion is provided by the rotating milling cutter. The two basic forms of milling are:

• Peripheral milling
• Face milling.

Other conventional machining operations include shaping, planing, broaching and sawing. Also, grinding and similar abrasive operations are often included within the category of machining.

We, at Indgirka have capability of custom manufacturer of precision CNC machined metal & plastic parts for the aerospace, automotive, computer and electronics, construction equipment, defence, medical, military, agriculture, railways, optical, and telecommunications industries. Capabilities include turning and milling services for prototypes through large production runs with very minimal tolerances. Materials worked which includes aluminum, brass, bronze, Inconel, mild steel, stainless steel, wood, plastic, ceramic, composits and PTFE. Multiple parts can be manufactured simultaneously.

Metal fabrication is the building of metal structures by cutting, bending, welding and assembling processes.

It is a value added process that involves the creation of machines, parts, and structures from various raw materials. After technical review and feasibility we will send details quotes, usually based on the engineering drawings, and if awarded the contract we will build the product as per requirement.

Welding is the main focus of fabrication. The formed and machined parts will be assembled and tack welded into place then re-checked for accuracy. A fixture may be used to locate parts for welding if multiple weldments have been ordered. We can use many welding processes which depends upon type of material and type of weld i.e.  MIG, TIG, ARC etc.

The welder then completes welding as per the engineering drawings if welding is detailed, or as per his/her own judgement if no welding details are provided.

Special precautions may be needed to prevent warping of the weldment due to heat. These may include re-designing the weldment to use less weld, welding in a staggered fashion, using a stout fixture, covering the weldment in sand during cooling, and straightening operations after welding.

After the weldment has cooled it is generally sand blasted, primed and painted. Any additional manufacturing specified by the customer is then completed. The finished product is then inspected and shipped to customer.

Casting is a manufacturing process in which a liquid material is usually poured into a mold , which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

We are having capability to work on below casting processes:

• Centrifugal casting (industrial).
• Core plug.
• Die casting.
• Glass casting.
• Investment casting.
• Lost-foam casting.
• Lost-wax casting.
• Molding (process).
• Permanent mold casting.
• Rapid casting.
• Sand casting.
• Slipcasting.

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer) or a die. Forging is often classified according to the temperature at which it is performed: cold forging (a type of cold working), warm forging, or hot forging (a type of hot working). For the latter two, the metal is heated, usually in a forge. Forged parts can range in weight from less than a kilogram to hundreds of metric tons.

The forging process can produce parts with superb mechanical properties with minimum waste. The basic concept is that the original metal is plastically deformed to the desired geometric shape—giving it higher fatigue resistance and strength. The process is economically sound with the ability to mass produce parts, and achieve specific mechanical properties in the finished product.

Forging of steel

Depending on the forming temperature steel forging can be divided into:

Hot forging of steel

• Forging temperatures above the recrystallization temperature between 950–1250 °C.
• Good formability.
• Low forming forces.
• Constant tensile strength of the workpieces.
• Warm forging of steel.
• Forging temperatures between 750–950 °C.
• Less or no scaling at the workpiece surface.
• Narrower tolerances achievable than in hot forging.
• Limited formability and higher forming forces than for hot forging.
• Lower forming forces than in cold forming.

Cold forging of steel.

• Forging temperatures at room conditions, self-heating up to 150 °C due to the forming energy.
• Narrowest tolerances achievable.
• No scaling at workpiece surface.
• Increase of strength and decrease of ductility due to strain hardening.
• Low formability and high forming forces are necessary.

For industrial processes steel alloys are primarily forged in hot condition. Brass, bronze, copper, precious metals and their alloys are manufactured by cold forging processes, while each metal requires a different forging temperature.

For other applications such as defence, railways, automotive, projects, construcations etc. a wide range of metals can be forged. Typical metals used in forging include carbon steel, alloy steel, and stainless steel. Very soft metals such as aluminum, brass, and copper can also be forged.

Forging of aluminium

• Aluminium forging is performed at a temperature range between 350–550 °C.
• Forging temperatures above 550 °C are too close to the solidus temperature of the alloys and lead in conjunction with varying effective strains to unfavourable workpiece surfaces and potentially to a partial melting as well as fold formation.
• Forging temperatures below 350 °C reduce formability by increasing the yield stress, which can lead to unfilled dies, cracking at the workpiece surface and increased die forces.

Due to the narrow temperature range and high thermal conductivity, aluminium forging can only be realized in a particular process window. To provide good forming conditions a homogeneous temperature distribution in the entire workpiece is necessary. Therefore, the control of the tool temperature has a major influence to the process. For example, by optimizing the preform geometries the local effective strains can be influenced to reduce local overheating for a more homogeneous temperature distribution.

Application of aluminium forged parts

High-strength aluminium alloys have the tensile strength of medium strong steel alloys while providing significant weight advantages. Therefore, aluminium forged parts are mainly used in aerospace, automotive industry and many other fields of engineering especially in those fields, where highest safety standards against failure by abuse, by shock or vibratory stresses are needed. Such parts are for example pistons, chassis parts, steering components and brake parts. Commonly used alloys are AlSi1MgMn (EN AW-6082) and AlZnMgCu1,5 (EN AW-7075). About 80% of all aluminium forged parts are made of AlSi1MgMn. The high-strength alloy AlZnMgCu1,5 is mainly used for aerospace applications.

Indgirka provides offshore services for the complete turnkey production of tubular parts and components. Whether it is cutting, forming or finishing of tubular parts, we do it all. This provides more complete parts that are closer to the end needs of your product. A full range of manufacturing and fabrication capabilities are available for your custom tubular parts, including:

• Cutting – Many cutting options are available. We use the method that provides the best, cleanest edge for the material used
• Bending &  Forming – We use single radius bends to any customer-specified angle with exceptional accuracy and consistency, with zero kinking.
• Punching &  Hole Drilling – We use many types of punched or drilled holes, in any size, based on what your designs dictate.
• End Forming – Numerous tube parts end formations are available, including angle cutting, notching/slotting, bevelling, and threading.
• Light Assembly
• Powder Coating, Painting & Plating and more

We do more of the work so you don’t have to! With all these manufacturing capabilities available from a single source, you’ll save valuable time and money on your next custom tubular parts project.

Custom molded rubber and plastic parts are being produced with exceptional quality and competitive pricing. Silicone, EPDM, Neoprene, ECO, NBR, Buna and Viton are available in a full range of typical durometers. Single cavity prototype and multi-cavity production tooling will be produced to your CAD file. Samples will be provided along with first article inspection reports.

Injection molding  is a manufacturing process for producing parts by injecting molten material into a mould. Injection moulding can be performed with a host of materials mainly including metals, (for which the process is called die-casting), glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed (Using a helical shaped screw), and injected (Forced) into a mould cavity, where it cools and hardens to the configuration of the cavity. After a product is designed, usually by an industrial designer or an engineer, moulds are made by a mould-maker (or toolmaker) from metal, usually either steel or aluminium, and precision-machined to form the features of the desired part. Injection moulding is widely used for manufacturing a variety of parts, from the smallest components to entire body panels of cars.

Compression molding is a high-volume, high-pressure method suitable for molding complex, high-strength fiberglass reinforcements. Advanced composite thermoplastics can also be compression molded with unidirectional tapes, woven fabrics, randomly oriented fiber mat or chopped strand. The advantage of compression molding is its ability to mold large, fairly intricate parts. Also, it is one of the lowest cost molding methods compared with other methods such as transfer molding and injection molding; moreover it wastes relatively little material, giving it an advantage when working with expensive compounds.