After the inspection of raw material in laboratory, the accepted
material is issued for pressing, also termed as heading on medium
& high speed machines depending upon ball size. The statistical
process control technique is used to monitor the machining allowance
& eccentricity. X Bar / R chart is used to monitor the ball
diameter variation. Pressed balls are regularly macro-etched to
detect the surface defects.
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Flashing
Pressed balls are put through plates having concentric grooves in
order to remove the pressed flash. The balls are continuously fed
into the grooves by means of specially designed feeding machine, so
that all individual balls travel equal distance during the process.
Plates are imported from Europe & grooving is done on precision
vertical turate lathe with DRO (digital read out system). This gives
uniform quality in the flashed balls to achieve better ball surface
hydraulic pressure system is used.
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Heat
Treatment
The heat-treatment gives the required hardness & homogeneity of
microstructure to attain maximum strength & durability in
compliance with material used. We provide the ball hardness as per
the customers’ application. Further if customer requires sub zero
treatment in addition we have a facility to provide it.
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Grinding
Grinding process is carried to make the ball diameter precise which
helps the next final lapping operation. To achieve better control on
size variation in balls feeding machines are designed which ensure
equal travel of balls through the grooved plates evenly.
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Work-Hardening
Work hardening process is carried out which increases surface
hardness of balls to avoid the handling damages in consecutive
operations by a special method.
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Lapping
Balls are lapped to the required finish size & surface to attain
the required quality grade. Lapping is carried out in two or three
stages depending upon customers’ quality requirements. Regular
monitoring by team of expert operators & quality auditors is
made to avoid any surface defects generated during the process.
After the final approval of the quality by Q.A. person the lot /
batch is unloaded carefully to avoid handling damages.
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Final
Inspection
After precision washing, oiling & before packing the sample
balls from the batch are sent for final audit to check surface
roughness, roundness, waviness, lot size variation and hardness in
sophisticated laboratory, according to specified control plan and
dock audit procedure. The test certificate is then prepared for the
customer. Our sophisticated laboratory is equipped with highly
precision world known machines & equipments and is managed by
trained & qualified personnel.
