Turning Casting Challenges into Production-Ready Components

Frigate successfully sourced and manufactured precision sand-casted GG-25 components, resolving dimensional variation issues from previous production runs. By implementing machining compensation and rigorous inspection processes, the components met the required tolerances and production specifications.

Industry

Industrial Equipment & Heavy Engineering

Core Capabilities

Sand Casting (GG-25), Precision Machining, CMM Inspection & Dimensional Validation

Country

India

5000+

Components Delivered

mm0.02

Tolerance Achieved

0.03 mm

Accuracy Maintained

99%

Inspection Compliance

Customer Key Challenges

Delivering precision GG-25 sand-casted components required addressing dimensional accuracy issues from previous production runs and ensuring strict tolerance compliance during machining and inspection.

Dimensional Runout Deviation

Previous orders faced runout issues, as casting runout was not compensated during machining, making it difficult to achieve the required dimensional tolerances.

Tolerance Control in Casting and Machining

Maintaining Inner Diameter tolerance of 0.02 mm and Runout tolerance of 0.03 mm required precise alignment between casting quality and machining processes.

Requirement Analysis

✔ Reviewed production order specifications and identified runout deviation issues from previous orders.

✔ Defined dimensional targets including Inner Diameter tolerance of 0.02 mm and runout tolerance of 0.03 mm along with inspection requirements.

Process & Engineering Planning

✔ Developed a machining compensation strategy to correct casting runout variations during finishing operations.

✔ Aligned casting and machining parameters to ensure dimensional stability throughout the manufacturing cycle.

Manufacturing & Quality Assurance

✔ Produced components using GG-25 sand casting followed by precision machining to achieve the required tolerances.

✔ Performed dimensional validation through CMM inspection and Material Test Certificates (MTC) to confirm compliance.

Delivery & Production Execution

✔ Manufacturing executed under Production Orders CCC1879 and P593.

✔ Production completed in collaboration with Aranga Engineering and Hindustaan Foundry, ensuring consistent casting quality and successful tolerance achievement.

Execution Process

We followed a structured execution process to correct dimensional runout issues, achieve tight tolerance requirements, and ensure consistent quality in GG-25 sand-casted components.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Heavy Steel Structural Fabrication Facility in Chhattisgarh

Structural steel fabrication Facility in Chennai

Structural Steel Fabrication Facility in Odisha

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Engineered Products for Critical Applications

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Turning Casting Challenges into Production-Ready Components