MAHABAL METALS PVT. LTD.

Chilled Camshafts – In House capabilities

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Camshaft Developments –
•Two part nos successfully developed meeting all specs
•Camshafts developed for 4 cylinder & 2 cylinder engines
•In house casting & finish machining
•In house cam profile inspection facility
•Castings in Sinto High Pressure line
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Cam shaft in-house casting capabilities

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4 Lobs

Oil Seal 1
Oil Seal 2
Total Length 462.0mm

In-house casting – 4 cylinder passenger car

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Customer Requirement of Hardness

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SPECIFICATION FOR CHIILED RESULTS

ZONE DEPTH & HARDNESS IN HRC
LOCATION HARD. DEPTH LOCATION 1 mm 2 mm 3 mm 4 mm 5 mm 6 mm 7 mm 8 mm
"O" 45 HRC 3 mm "O" 54 52 51 50 50 47
"A" 45 HRC 3 mm "A" 50 49 48 48 48 46
"B" 45 HRC 3 mm "B" 51 50 -- 48 46 45
"C" 40 HRC 3 mm "C" 50 48 46 46 45 44
"D" 40 HRC 3 mm "D" 48 46 46 44 43 40
"E" 30 HRC 1.5 mm "E" 35 33 32 30 29
"F" 30 HRC 1.5 mm "F" 35 33 31 30 29
"G" 30 HRC 1.5 mm "G" 36 32 32 30 29

Actual Result of Hardness As Cast

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MICROSTRUCTURE OF CHILLED ZONE

DESCRIPTION SPECIFICATION RESULTS
80% MIN. CARBIDE CEMENTITE + 80% MIN. CARBIDE CEMENTITE +
EUTECTIC CARBIDE
PEARLITE, FREE FROM GRAPHITE PEARLITE, FREE FROM GRAPHITE

MOTTLED ZONE
DESCRIPTION SPECIFICATION RESULTS
CARBIDE + PEARLITE , D & E CARBIDE + PEARLITE , SOME D & E
TRANSFORMATION ZONE
GRAFITE GRAFITE

MICROSTRUCTURE OF GREY ZONE

DESCRIPTION SPECIFICATION RESULTS
FLAKE SIZE 3 TO 6 3~6
CARBIDE 15% MAX. 5%
FERRITE 5% MAX. 1%
TYPE SOME D & E GRAPHITE SOME D & E GRAPHITE

Microstructure Result of Grey Zone

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OIL SEAL CORE

CHILLED ZONE

MICROSTRUCTURE OF CHILLED ZONE

DESCRIPTION SPECIFICATION RESULTS
EUTECTIC CARBIDE 80% MIN. CARBIDE CEMENTITE + 80% MIN. CARBIDE CEMENTITE + PEARLITE,
AT LOCATION 'A' & 'B' PEARLITE, FREE FROM GRAPHITE FREE FROM GRAPHITE

MICROSTRUCTURE OF OIL SEAL CORE

DESCRIPTION SPECIFICATION RESULTS
SOME D & E
TYPE SOME D & E GRAPHITE
GRAPHITE
CARBIDE 15% MAX. 10%
FERRITE 5% MAX. NIL

Microstructure Result of Chilled Zone

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CAM LOBE

INTER CAM

SPECIFICATION RESULT

HARDNESS HARDNESS

180 - 230 BHN 207 BHN

NOTE :- CHILLED PROFILE IN AS CAST CAM

SHAFT

Hardness Result Of Inter Cam

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OIL SEAL CORE

CHILLED ZONE

RESULTS
SPECIFICATION
DEPTH & HARDNESS IN HRC
HARDNESS DEPTH 1 mm 2 mm 3 mm 4 mm 5 mm 6 mm
HARDNESS OF OIL
40 HRC 4 mm 44 44 42 42 40
SEAL CHILL AT 'A'
HARDNESS OF OIL
40 HRC 4 mm 45 45 44 42 40
SEAL CHILL AT 'B'

HARDNESS OF OIL
229 TO 302 BHN Ø 10 mm MIN 250 BHN
SEAL CORE

NOTE :- CHILLED PROFILE IN AS CAST

NOTE :- CHILLED PROFILE IN AS CAST CAM SHAFT
CAM SHAFT

Hardness Result Of Oil Seal

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In House machining capabilities

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Cam shaft in house machining cell –

•Centering

•CNC Turning

•Rough cam lobe grinding

•Finish cam lobe grinding – NTC , Japan

•Cam lobe data measurement – ADCOLE,USA

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SR.NO. DESCRIPTION
1 M/c. Model NTG-CMS3563
2 M/c. Make NTC Japan
3 M/c. size Ø350mmX630mmLength
4 Grinding Wheel Type Cbn Wheel
5 Grinding Wheel Speed 120 mps
6 Grinding Wheel Dia. Ø350mm Max.
MAHABAL METALS PVT. LTD.

CNC Camlobe finish grinding machine

MAHABAL METALS PVT. LTD.

CNC Camlobe super finishing machine

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ADCOLE MEASURING MACHINE

SR.NO. DESCRIPTION
1 M/c. Model 1200-3.8" Single Head
2 Max. Length of Component 965mm
3 Swing Dia Ø302mm
4 Gage Accuracy <0.5µ
5 Touch Screen Control -

6 ** Can Measure Critical Parameters of Cam Shaft & Crank

Shaft.
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Cam lobe profile measuring eqpt – EasyCam(Andrews, USA)

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Cam lobe critical parameters - capability
CAM LOBE PARAMETER ACCURACY
Achieved
SPECIFICATION/TOL
SR.NO. PARAMETER Tolerances
ERANCE

1 Tip Angle ± 0.5 ± 0.25

2 Max. Lift ± 0.05 ± 0.025
3 Base Circle Radius ± 0.05 ± 0.025
4 Base Circle TIR 0.03 0.025
5 Base Circle Roundness 0.03 0.020
Maximum Profile Errors
1 Tip 0.04 10 - 15µ
2 Flank 0.04 10 - 15µ
3 Ramp 0.04 10 - 15µ
4 Velocity Error ± 0.004 2 - 3.5µ
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Part photos…