ABI Group – Organization Chart

R. Srikanth
MD

K. Sundar
ED

R. Balaji V. Senthilvel
K. Kannan
VP - DGM –
VP - Foundry Marketing
Machining

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ABI Group - Footprint

 1991 – Incorporation of ABI Showatech India Limited [ABI]

 ABI traces its lineage to the TVS Group – A Leading player in Indian Automotive
Component Industry.

 1995 – Incorporation of Light Alloy Products Limited [LAP] [100% subsidiary of ABI]

 ABI & LAP supply brake-parts and turbocharger parts.

 2005 - LAP JV with Ross Casting and Innovation [RCI] to form LAP-Ross Engineering
Limited [LRE].

 2011 - LAP and Hitchiner Inc. – Technical collaboration agreement for Turbine Wheels

 2013 - ABI acquired RCI

 2013 – Merger of LAP and LRE with ABI

 ABI Group sales in 2016-2017 was greater than INR 500 Crores (~ USD +90 Million)

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ABI Group – Business Chart

ABI SHOWATECH
INDIA LTD

Aluminum Super Alloys

Ferrous Division Division Division

Turbine Housing Bearing Housing Stainless Steel Turbine Turbine Wheel

Housing

Compressor Compressor safety critical parts

Wheel Housing [Brakes Parts]

USA India China

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ABI Group – Process Capability

ABI

Casting Machining

Plaster Mould
Gravity Die Investment CNC Machining 5-Axis Milling Assembly
– Counter
Casting Casting
Gravity

Hind Hivac -
Hitchiner
High Vacuum

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Process Highlights
Process Key Highlights

Investment Casting –  Technical collaboration with Hitchiner for Manufacturing of

Hitchiner – CLI-C3 Investment parts
 Capability to cast different Alloy’s [Inco 713C / MAR M246 /
GMR]
 Ability to Cast parts with excellent Microstructure
Investment Casting – Hind  Melting and Casting under Vacuum
Hivac  Capability to cast various high temperature alloy’s

Plaster Mould Process –

Counter Gravity  Ability to cast thin parts up to 0.3 mm
 Capability to produce any intricate shape aluminium Alloy
casting
 In-house HIP facility

Gravity Die Casting

 Internal Tool / Mould manufacturing
 Capability to melt 60 Tons of aluminium / day
 Carousel based gravity pouring

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Process Highlights

Process Key Highlights

Stainless Steel Foundry  Resin bonded Sand process
 Capability to cast any Air melted material
 Robotic coating
 700 X 700 horizontal core shooting machine
Machining  Proven Expertise and capability to Machine high precision and
safety critical components
 Facility and Capability to do 5-Axis Milling
Others  Certified to TS 16949, ISO 14001, OSHAS 18001 and TPM.
 Government recognized R&D center
 Complete metallurgical, chemical, and testing laboratories at
ABI

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Products portfolio

 Our Product Portfolio consists of Safety Critical & Precision parts (Brake parts)
|Turbo charger parts | Aluminum Parts | Stainless steel parts | Housings, Etc.

 We are equipped with both Casting and Machining Facility .

 The Brake parts includes Master Cylinder , Wheel Cylinder, Clutch Boosters,
calipers, Pistons .

 Turbo Charger parts includes Compressor Wheel , Turbine Wheel , Bearing

housings, Compressor Housings and Turbine housings.

 Housings include in Line Pump Housing , Steering Housing , Radiator Tanks ,

Gear Housings, etc.

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Products | Location | Volume

Product Plant Location Average Volume Per annum

Master Cylinder India 2.70 Million
Wheel Cylinder India 2.90 Million
Caliper India 0.04 Million
Compressor Wheel India, USA and China 7.00 Million
Turbine Wheel India 1.40 Million
Bearing Housing India and Oman 3.50 Million
Turbine Housing India 0.60 Million
Compressor Housing India 1.30 Million
Bearing Cap India 1.30 Million

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Casting

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Gravity Die Casting

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Gravity Die casting Process

Modeling and Simulation Manufacture of tools Melting Furnace

Casting facility – Horizontal and Vertical Parting line cell

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Gravity Die casting Process

Conveyor based – Core and Casting Handling

Heat Treatment
100% Visual inspection, Packing and Dispatch

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Investment casting - Hitchiner CLI-C3
process
Hitchiner Process Flow

Modeling and Simulation Manufacture of Wax Stem

Manufacture of tools and Patterns

Assembly of Wax Pattern Shell Making and Drying Rotary de-waxing of shells

Pre Firing of Shells Washing of shells Firing of Shells

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Hitchiner Process Flow - Continued

Pouring and Casting Knockout / De-Moulding Shot Blasting

100% FPI 100% Visual inspection Packing and Dispatch

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Counter-Gravity Plaster Mould Process

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Compressor Wheel - Process
Mould Making

APF Knockout Riser Cutting

Shot blasting Initial Inspection HIP

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Compressor Wheel – Process - Continued

Heat Treatment 100% Ultrasonic Testing 100% FPI

100% Visual inspection Packing and Dispatch

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Stainless Steel Foundry

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PROCESS FLOW
Raw
Raw Material Material Core Core
Inspecti Melting
Receipt Manufacturing Painting
on

Initial Shot Core Core

Knock Out Pouring
Blasting Assembly Heating

R&R Cutting Final

Shot Blasting DP Testing Inspecti Dispatch
& Fettling on
Product Footprint

 Chemical Composition
 1.4826
 1.4848
 1.4849
 1.4837
 Any other Air melted material
 Weight Range
 2.5 – 7 Kg
 Volumes
 100 K – 300 K per part number / Annum
 Capability to produce Single Scroll / Twin Scroll / Integrated Manifold
 Capability to supply as assembled Turbine Housing
Proposed Plan for New Foundry

 Capacity – Scalable to One Million Parts Per Year [Approximate 3000 Metric

Tonnes]

 Process – Resin bonded Sand

 Casting – Automatic Pouring - Counter Gravity

 Flexibility to accommodate other casting process based on requirements

 Integrated machining shop would be setup to support the casting volume

Machining

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Machining

 ABI is specialized in turned parts, milled parts with secondary operations like
turning, drilling, milling , honing , grinding ,heat treatment etc.

 State of the art resources comprising of CNC turning centre's, turn mill centre's,
Assembly machines, honing machines, Testing Machines and a number of
conventional production machinery to manufacture a finished part

 Facility and Capability to do 5-Axis Milling

 Proven Expertise and capability to Machine high precision and safety critical
components

 Total Number of Machines at ABI is 350+

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Machining

Machining

Non-
Ferrous
Ferrous

Turbine Bearing Turbine Master Wheel Compressor

Caliper
Housing Housing Wheel Cylinder cylinder Wheels

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Machining Facilities at site

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Machining Facilities at site

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Machining Facilities at site

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Machining Facilities at site

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 Milled Wheel
Or
Fully machined Wheel from Bar / Forged blanks

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Process Flow

OP 10 – Cutting OP 20 - Back OP 30 – Blade

and Rough face & Bore Profile & Height
Machining Machining Machining

OP 50 –
OP 60 – OP 40 – 5 Axis
Balancing &
Washing Milling
Correction

OP 70 –
OP 80 -
Inspection and
Despatch
Packing
Material Flow

Raw Material Rough / Forged Blank Back face

Machining

Blade Profile 5 Axis- Blade Balancing Despatch

Machining Machining
Design - Tool Room Facilities

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In-House Tool Design Facilities

Capability to design tools / jig / fixture. We are equipped with the

required hardware and software.

TOOL DESIGN WITH PRO-E

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Facilities – Tool room for tools manufacture / regrinding

5 AXES TOOL MAKING MACHINE

6 AXES TOOL MAKING MACHINE

We are equipped with 6 & 5 axis CNC
tool and cutter grinder for
manufacture of cutting tools.

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Facilities – Tool room for Jigs / Fixtures manufacture

Our Tool Room setup is

equipped with CNC milling
machines / grinding machines
/ heat treatment and fitting
facilities .

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Products - Snapshot

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Gravity Die Casting products
Clutch Booster Master Cylinder Piston Brake Caliper

Pressure Block Radiator Tank 39

Gravity Die Casting products
4 Cylinder Housing 3 Cylinder Housing Master Cylinder

Master Cylinder Steering Housing Wheel Cylinder

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Gravity Die Casting products
Compressor Housing Steering Gear Housing Hub Strut

Compressor Housings 41
Investment casting [Hitchiner and Hind Hi-Vacuum] Products
Turbine Wheels

Guide Vanes Bushes

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Counter Gravity Plaster Mould Process – Compressor Wheels

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Counter Gravity Plaster Mould Process - Water Impellers , Super Charger and
Inter-Cooler .

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Turbine Housing for Turbo chargers

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Bearing Housing for Turbo chargers

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Master Cylinders

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Wheel Cylinders

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Caliper’s

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Fully Machined From Bar - Compressor Wheels

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Stainless Steel Products – Turbine Housing

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LAB and Quality Testing Facilities

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Lab and Quality Testing Facilities at ABI

Hardware
 Scanning Electron Microscope (SEM)
including EDX capability
 Geometric Optical Measurement – GOM
 CMM
 Thermal analysis equipment
 Creep testing equipment
 Vacuum testing and analysis equipment
 Multiple elevated temperature fatigue
testing equipment
 Natural frequency tester
 Complete metallographic and
microscopy laboratories
 Elevated temperature tensile
testing equipment
 Profile Projector
 Moisture analyzer

Software
 Pro-E-Design  Weibull reliability
 AutoCad  Grain structure analysis
 Magma Soft  Procast
Incoming Material Testing

Spectrometer for analysis of major ICP OES to check trace elements such as
elements of the alloy Te, Ag, PB, Bi, Se, etc at 1 ppm level

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Incoming Material Testing

Leco O2 & N2 analyzer to analyze

Oxygen and Nitrogen presence at 2
PPM level.

Leco C, S, analyzer to analyze carbon

and Sulphur

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Quality Testing Facilities in the site

Creep Testing at elevated temperature Tensile Testing At Elevated

Machine Temperature

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Quality Testing Facilities in the site

UTM Vickers Hardness Test

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Quality Testing Facilities in the site

Millipore Apparatus

Magnetic Particle Crack

Universal Testing Machine
Detection Machine
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Quality Testing Facilities in the site

Customised Boroscope 3D Height Master Tool Presetting Machine

Opto Electric Measuring Spring load Testing

2D Height Master Machine 59
Machine
Quality Testing Facilities in the site

Surface Roughness Testing Roundness Testing

Machine Machine

Cylindricity Testing
CNC CMM Machine
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Quality Testing Facilities in the site

Rockwell Hardness Tester Micro Hardness Tester

Profile Projector with

Contour Tracer Auto Edge sensor 61
Laboratory Measurement Facilities

CMM GOM

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Laboratory Investigative Facilities

SEM With EDS

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 CERTIFICATES

Quality - ISO TS 16949 : 2009

EMS - ISO 14001 : 2004
Safety – BS OHSAS 18001 : 2007
TPM - Excellence

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Snaps of Certificates

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CSR

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CSR

We as a group are obligated to our society and we show our gratitude in many ways.
Some of them are :

 “Vidhya Peetam School” established to provide quality education to the children

in Sholinghur area
 “Matrix Technical Training Institute” was established to impart excellent
technical training and education
 “Siksha Kendra” a training school established to impart knowledge on
Turbochargers
 Support to SMF (Sundaram Medical Foundation) – Community hospital

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ABI Group – Customers

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 THANK YOU

Contact:
+91- 4172-308441 | abimarketing@abishowatech.co.in