Prakash Projects Heavy Forged Division
The Shin Nippon Koki CNC planer-miller spanning its bed.

Infrastructure

The melting shop, the radial forge, the presses and the machine shop, with the working capacity of each.

5,000M.T.
Largest press
1400°C
Reheating to
90+
CNC machines

Forging

Three forging routes. The route for a job is decided by its shape and diameter.

  • Four dies closed around a billet at forging heat inside the radial forge.

    Hydraulic radial forge

    Up to 200 forging strokes per minute

    Four opposed cylinders in an X, closing in synchronised strokes. Two manipulators grip, position and rotate the work, tied to the press by PLC and SCADA. In: ingot cast, continuously cast or preformed. Out: bars, tubes, shafts, axles. India’s first, and the world’s second largest.

  • A forging manipulator holding a glowing workpiece to the press.

    5,000 M.T. hydraulic forging press

    Up to 3 m diameter

    Paired with a 30 tonne-metre forging manipulator.

  • 1,500 M.T. hydraulic forging press

    Up to 1.2 m diameter

    Paired with a 10 tonne-metre forging manipulator.

Furnaces

  • An ingot at forging heat on the hearth of a gas-fired reheating furnace.

    Gas-fired reheating furnaces

    Up to 1400 °C

    Multiple furnaces, each fitted with recuperators that recover heat from the exhaust gas.

  • A rail-bound manipulator drawing a glowing bar out of the furnace bay.

    Rail-bound loading / unloading manipulators

    2 units

    Charge and draw the furnace without letting the ingot stand and lose heat.

Heat treatment

Normalising, annealing, quenching and tempering, all in-house.

  • Forgings glowing in rows inside the bogie furnace during normalising.

    Gas-fired bogie-type furnaces

    Up to 1200 °C

    Multi-zone temperature monitoring, so a long shaft heats evenly along its length.

  • A charge of shafts inside the electrical tempering furnace.

    Electrical tempering furnaces

    Up to 800 °C

    Stable, closely controlled low-temperature cycles after quenching.

  • A bar at quenching heat lowered on chains into the polymer quench tank.

    Polymer quench tank

    2.5 × 3.5 × 9 m

    Quench severity is adjustable, which is how the hardness and toughness are balanced against each other.

  • A forging entering the oil quench tank, flame lifting off the surface.

    Oil quench tank

    2.5 × 3.5 × 9 m

    Uniform cooling, less distortion.

Machining

More than 90 large-capacity CNC machines, supported by a conventional machine fleet.

Machine counts and capacities as last verified with the plant.
Type CNC Manual Envelope
Lathes 28 25 Ø 1,200 mm × 16,000 mm
Vertical turning lathes 5 10 Ø 5,000 mm × 3,000 mm height
Horizontal / vertical machining centres 16 8 3 m W × 12 m L × 2.5 m H
Grinders 2 7 Ø 1,100 mm × 10 m
Deep-hole drills, hydraulic 6 — 1,200 mm swing × 10 m
Radial drills 4 — 2 m swing × Ø 65 mm
Tapping machines 5 — Up to M48

Also available: cylindrical grinding, precision boring, milling and drilling.

A single integrated site

All of the above is located at our Pilkhuwa works. A part is cast, forged, heat treated, machined and packed without leaving the site.

  1. Plant

    Khasra 225/226, Masota Road, LakhanPilkhuwa, HapurUttar Pradesh, India

    Melting shop, radial forge and CNC machine shop.

Send us your drawing

Tell us the shape, grade and quantity, and you will receive a reference number immediately.

Send a drawing