Spur and Helical Gears used in Bi - Wheelers and other Automobiles Transmission Gear Boxes as well as in Pumps . Timing Gears as well as Splined Axle Shafts for above applications.

Gears having Standard and Modified Profiles with both plus and minus profile correction factors, Straight Splines and Shafts Gun Drilled thru' with dia 5 ~ 8 mm (at present) and a possibility of dia 25 mm x 200 long.

All Gears and Shafts are produced to a class of accuracy JIS 5 as per Japanese Industrial Standards equivalent to Class of accuracy 9 as per DIN 3967.

Alloy Steels SAE 8620 , En 8D and SCM 415 H / SCM 420 H necessarily of Mukund Steel Ltd. / Vardhaman Special Steels to ensure proper chemical composition both for Hot and Cold forging practices. Proper records are kept for easy traceability should the need for some investigation arise.

Very special care taken in Heat Treating the components in Sealed Quench Furnaces (SQF) with computerized controls to ensure strict control on the Effective Case Depths and Microstructure. The SQF does not allow any De-carb which might result in soft spots on the treated surfaces.

We have a TIE - UP with M/s METALS INDIA - Faridabad for heat treatment on our components and have got their plants duly approved from a senior technical Japanese team from Yamaha Motor India (P) Ltd. The source has the following equipment to ensure the desired treatment;

6.1 Sealed Quench Furnaces , Wesman Ipsen make - 2 Nos. In straight through design with Super Carb ( Air + LPG ) process and gas Nitriding process with oil quench and forced gas quench facility. The furnaces are electrically heated fitted with thyristor control unit for supplying power to furnaces and fitted with Allen Bradley PLC model SLC - 5/30 for furnace logic controls, complete with Loader / Un-loader , electrically heated pre-heating furnace , Tempering furnace and Washing Machine.

6.2 Nitrogen Generator

6.3 CO Analyzer

6.4 Table type double door Shot Blasting machine.

6.5 Ultrasonic cleaning machine

6.6 Back up power thru' Gen Set

6.7 Micro Hardness Tester with Image analyzer

6.8 Induction Annealing machine

6.9 Brinnel , Rockwell & Superficial Hardness testing machines

The plant is completely computerized.

Metals India is presently catering to the following main customers:

Hero Honda group

Honda Ciel

Honda Scooters

Yamaha

Baker Oil Tools

Processes being regularly undertaken at Metals India:

Carburizing

Nitriding

Carbonitriding

Nitrocarburizing

Neutral Hardening

Annealing, Normalizing, Isothermal Annealing & Stress Relieving.

The effective case depths are maintained between 0.40~0.60 mm at heat treatment stage achieving a surface hardness of 78 ~ 82 HRA values. The threaded portions wherever applicable are kept "Soft" by preventing them from getting carburized by application of ' Anti-carb Paste' which prevents carbon penetration on threads during carburizing process on rest of the part. Never the less the threads are Induction Softened" after heat treatment to ensure soft threads having a hardness level of less than 70 HRA as per Yamaha specifications.

To manufacture any Gear or Shaft to the required perfection level it is very important that the selection of the special tooling gets an utmost and careful consideration failing which the desired accuracies can never be achieved despite best expertise and efforts. At Kalson such care is always taken and the RISK factor is zero. We buy only CMH ( formerly Chogule Matrix Hobs Ltd - Hyderabad ) Gear Cutting Tools manufactured out of ASP 30 Material and the Spline Broaches are procured from the ever dependent Dagger Forst Tools . By doing this we, at Kalson, ensure that the components coming out shall conform to the desired accuracy levels.

The components after all operations are subjected to Quality Audits at the hands of experienced Quality Assurance Engineers to ensure that the customer gets a PRODUCT ENGINEERED TO PERFECTION. At Kalson we assume that our final QA Engineer is a representative of our customer, even though the systems set do not have chances of any quality deviations.