1. Presentation
on
Manufacturing Capability & Facility
for
Undercarriage Rollers & Links

2. 2800 Ton Forging Press Line @ Varroc, Aurangabad
2800T Forging Press Line with 1500 KW Induction Heater
* 2500 T Forging Press expected in December ‘13

3. Hot Forging of Rollers
@ Varroc – IMES, Italy

4. Hot Forging of Links
@ Varroc – IMES, Italy

5. Heat Treatment Facilities, @ Varroc, Aurangabad
Heat Treatment Furnace SCADA Software display on
Plasma TV

6. Shot Blasting Facility

7. Roller Machining Facility
@ Varroc – IMES, Italy

8. Roller Machining Facility
@ Varroc – IMES, Italy

9. Tool Room Facility
•Vertical Milling Machine – HAAS / FADAL / DMG / JYOTI
•Horizontal Milling Machine. – HMT
•Wire cut Machine – ELECTRONICA
•EDM Machine – ELECTRONICA
•Surface plate – METROLOGY
•Hack saw machine – INDOTECH / ITL
•Drilling machine – HMT
•Conventional lathe and milling machine – HMT
•Die finish unit – UTCON

10. Tool Room Facility
Fadal High Speed Vertical Milling m/c ACE CNC Hard Turning m/c
Joemars Spark Erosion Joemars Wire Cut

11. Key Quality Assurance: Standard Room
Gear Tester (Hofler Make) Gear Tester Machine (TTI Make)
Co-ordinate Measuring Machine (CMM) Profile Projector with
Data Processor

12. Key Quality Assurance: Standard Room
Roundness Tester Form Tracer / Contracer (Mitutoyo Make) 2D Height Master
Metallurgical Microscope with Image Hardness Shimadzu (Japan) Make Optical
Analyser – Zeiss Make Tester Spectrometer

13. Engineering Infrastructure
The Design & Engineering facility comprises of:
 CAD/CAM/CAE infrastructure for 3D modeling, NC tool path generation and FEA analysis to accelerate
response time in developing new parts.
 Metal flow simulation software "FORGE 3“ from M/s. Transvalor, France used for virtual manufacturing,
Process validation, die stress analysis, to estimate forging load, grain flow, tool life, Material life and design
optimization to develop new parts right the first time.
 High-end CAM software, like “Delcam“ and "UG-NX" for generating NC tool paths for high-speed die
cutting, to reduce turnaround time in die manufacturing.
 Software include • FORGE 3 Ver. 2011 on 9 CPU Cluster
• Finite Element Analysis (Ansys 11.0)
• Hyper mesh 21HWU
• 3D Modeling (Unigraphics NX-5)
• 3D Modeling (Pro Engineer)
• 3D Modeling (Catia V5 R18)
• Machining Program (Power shape 7.2)
• Machining Program (Power Mill 8.0)
• Drafting (AutoCAD)

14. 3D Modelling

15. Forging Simulation & Analysis

16. Advantage Varroc – Undercarriage Products @ Varroc – IMES, Italy
Link & Rollers Segment
Hub Link Segment

17. Client List – Varroc – IMES, Italy
CAT – MECTRAC, Bologna, Italy
CAT – Grenoble, France
SMITH – Italy
HUGHES – UK

18. THANK YOU