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ABOUT THE COMPANY

RICO is a world- class engineering group supplying a wide range of high precision fully

machined aluminum and ferrous components and assemblies to automotive OEMs across the

globe. RICOs integrate services include design, tooling, casting, machining, assembly and R&D

across ferrous and aluminum products.

RICO GROUP OF INDUSTRIES

TABLE 1.1

COMPANY NAME PARTNERSHIP PRODUCTS

FCC RICO 50% FCC & 50% RICO Clutch assembly two

wheelers and four wheelers

CONTINENTAL RICO 50% CONTINENTAL &

50% RICO

Hydraulic Brake products and

services

MAGNA Powertrain RICO 50% MAGNA Powertrain &

50% RICO

Oil pump and Water pump

RICO JINFEI 92.5% RICO & 7.5% JINFEI Aluminum Alloy Wheels-

Two Wheelers

RICO USA& UK 100% RICO Assembly, logistics,

Customer support

TABLE 1.2. RICO IN INDIA

COMPANY NAME LOCATION PRODUCTS/PROCESSES

DHARUHERA Dharuhera Aluminum Casting and

Machining

RICO GURGAON Gurgaon Aluminum /Ferrous Dies &

Moulds, R&D, CAD/CAM

CAE

RICO HARIDWAR Haridwar Aluminum Casting &

Machining

RICO BHIWADI-1 Bhiwadi Machining

RCL LUDHIANA Ludhiana Ferrous Casting & Machining

RCL MANESAR Manesar Aluminum Casting &

Machining

FCC RICO Manesar Manesar Clutch Assembly

FCC RICO Pune +RICO

Pune

Pune Machining

CONTINENTAL RICO Gurgaon Hydraulic Brakes

MAGNA RICO Dharuhera Oil and Water Pump

RICO JINFEI Manesar Aluminum Alloy Wheels

RICO Chennai Chennai Aluminum Casting and

Machining

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RICO AUTO INDUSTRIES DHARUHERA

LOCATION:-

69 K.M STONE, DELHI- JAIPUR HIGHWAY,

DHARUHERA(H.R)

CERTIFICATION:

ISO9000-1994

QS-1998

ISO 1401-2002

OHSAS 18001-2002

CAPACITY :

Over 16 million high pressure die cast components are produced per annum.

FUTURE PLANS OF THE FIRM :

Reduce dependency on other industrial sector.

Searching for new customers

Expansion of the firm.

Investment in the other profitable industrial sectors.

PRODUCTS AT RICO DHARUHERA

Table 1.3

PRODUCTS CUSTOMER

Clutch Assembly(2 Wheeler) Hero-Moto Corp

Wheel Hub Assembly(2 Wheeler) Hero-Moto Corp

Brake Panel Assembly(2 Wheeler) Hero-Moto Corp

CUSTOMERS:-

Hero Moto Corp

Maruti Suzuki

Ford Motor Company

Volvo

Cummins

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5-S OF THE COMPANY :

SEIRI (SORTING)

SEITON (SYSTEMATISING)

SEISO (SHINING)

SEIKETSU (STANDARISATION)

SHITSAKE(SELF DISCIPLINE)

UTILITY :-

Maintenance department is responsible for the management and supply of electricity and

compressed air to different section of firm.

Power comes from HVPNL (HARYANA VIDYUT PARISHADH NIGAM LTD.) 1,30,000

Kw-h / day

Generated voltage 11 KV

Compressor : 2200 CFM

Screw type compressor used.

Fig 1.

RICO DIES PRODUCTION SHOP :

RICO dies unit molds (machines) the dies required in the HPDC Shop.

It involves manufacturing of new dies and maintenance of old once.

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CAD/CAM DIVISION :

Function of this unit is product design, tool design, jig design, etc.

AUTOCAD software was used by the department for 2D layouts

Pro E and CATIA were used for 3D Design and Modelling

CNC Machines were coded through LAN system. Code is generated on CAM and uploaded in

CNC Machines through LAN system.

Fig 2. RICO Dharuhera

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MASTER PRODUCTION CHART :-

FLOW CHART 1.

RAW MATERIAL:-

ADC-12 & ADC-14 alloys

FURNANCE (MELTING):-

Electric Arc Furnace is used to melt the raw aluminum into liquid metal

An electric arc furnace (EAF) is a furnace that heats charged material by means of

an electric arc.

Alloys are melted in a furnace at 1000C.

Raw Aluminum is brought to the furnace on conveyor belts.

When the Aluminum enters the red hot furnace maintained at 1000C aluminum melts

This liquid Aluminum passed to molding machines through channels (pipes) which pour

the molten metal into a reservoir.

Each injection molding have a separate reservoir.

RAW MATERIAL STORAGE

FURNANCE (MELTING)

HIGH PRESSURE DIE CASTING

HEAT TREATMENT

MACHINING ROW (TURNING, DRILLING , etc.)

QUALITY UNIT

PAINT SHOPPACKAGING AND

STORAGE

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Fig 3. Electric arc furnace

FOUNDARY SHOP

HIGH PRESSURE DIE CASTING:-

Here, the liquid metal is injected with high speed and high pressure into the metal

mold.

The basic equipment consists of two vertical platens.

The bolsters are placed on these platens and this holds the die halves.

Out of the two platens, one is fixed and the other movable. This helps the die to open

and close.

A specific amount of metal is poured into the shot sleeve and afterwards introduced

into the mold cavity. This is done using a hydraulically-driven piston.

After the metal has solidified, the die is opened and the casting eventually removed.

Fig 4. High Pressure Die Casting

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TYPES OF HIGH PRESSURE DIE CASTING PROCESS

Hot Chamber Process

Cold Chamber Process

Hot Chamber Process:-

The hot-chamber process is applicable only for zinc and other low melting

point alloys that does not affect and erode metal pots cylinders and plungers.

The molten metal for casting is placed in the holding furnace at the required

temperature adjacent to (sometimes as part of the machine itself) the machine.

The injection mechanism is placed within the holding furnace and most of its

part is in constant touch with the molten metal. When pressure is transmitted

by the injection piston, the metal is forced through the gooseneck into the die.

On the return stroke, the metal is drawn towards the gooseneck for the next

shot.

This process ensures minimum contact between air and the metal to be

injected. The tendency for entrainment of air in the metal during injection is

also minimized.

Fig. 5 Hot Chamber Die Casting

Cold Chamber Die Casting:-

The injection system is not submerged in molten metal.

Metal gets transferred by ladle, manually or automatically, to

the shot sleeve.

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The metal is pushed into the die by a hydraulically operated

plunger. This process minimizes the contact time between the

injector components and the molten metal.

The entrainment of air into the metal generally associated with

high-speed injection can cause gas porosity in the castings. In

the cold chamber machine, injection pressures over 10,000 psi

or 70,000 KPa is obtainable.

Fig 6 Cold Chamber Die Casting

RICO DIE CASTING (HPDC UNIT) :-

18 high pressure die casting machines in the HPDC SHOP

In HPDC machine two dies are used :

Fixed die ( cover die)

Movable die (ejector pins)

These machines have different locking force like 660 ton, 560 T, 400 T, 250 T, 200 T,

160 T, 135 T.

Dycote is used for cooling of the die.

The die is also cooled by water for efficient cooling of the casting. This increase dies life.

HPDC machine is controlled by three factors :

Accumulator pressure

Nitrogen pressure

Die opening time

Nitrogen pressure is produced with the help of nitrogen gas.

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Nitrogen gas pushes the piston accumulator and thus accumulator pressure is produced.

The time between closing the die for casting to the opening it, is called die opening time.

PROCESS:-

Spray the mold with lubricant and close it. This helps to maintain the inside temp. Of

the die and also allows easy removal of cast product.

The nitrogen gas increases the accumulator pressure and the molten metal is injected

into the shot sleeve.

The metal is injected at very high pressure which ensures the precise shape of cast

object.

After the mold fills completely, it is allowed to cool under high pressure.

Open the die and cast product is removed with the help of ejector pins.

COMPONENTS MADE IN HPDC SHOP :-

Outer clutch

Centre clutch

Friction disc

Lifter plate

Pressure plate

Front & rear hub

Front & rear brake panel

TYPES OF COOLING IN HPDC SHOP :-

SPOT COOLING: The cooling is done at particular spots only.

LINE COOLING: Continuous cooling is done. An entire region is cooled by this.

FUNCTION OF DYCOTE :-

( Filler + bonding agent + water )

The principal functions required of a coating for die casting are:

Control of the metal flow to ensure that it reaches all parts of the die at a

sufficient temperature to prevent the formation of seams, cold laps, etc.

Control of heat transfer to obtain better solidification and ensure that the castings

are properly fed.

Good surfaces, and therefore a reduction in finishing costs

Longer die life, therefore increased productivity and reduced maintenance and

cost.

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FACT :-

The layer of DYCOTE with a coarse surface, the contact between molten metal and

DYCOTE is significantly re