Showcase

Our strengths in process planning, tooling and development, programming, and the best-sourced finishing, enable us to execute a diversity of precision machining and assembly projects. Showcased below are examples of ongoing projects, detailing the challenges, approaches, outcomes and highlights of each.

  • BRACKETS & HOUSINGS
  • LOCO RING KIT
  • BRAKE COMPONENTS

Challenge: Rapid development of 21 complex parts, in aluminium and steel, for a US$ 14 billion aerospace giant.

Approach: Zenith executed this project by evolving an optimal manufacturing sequence best suited for the volumes, designing and manufacturing specialised fixtures, selecting latest technology tools and engineering services (including PPAP & PFMEA). We had a SPOC work closely with the customer to ensure swift responses and on-time completion of project.

Outcome: Based on our ability to sustain demanding quality standards and consistently supply on time (while also offering substantial cost savings), we helped our customer address his supply chain risk by ensuring uninterrupted production and delivery schedules.


Project Highlights


Product Description Brackets & Housings (components & sub-assemblies)
Machining Processes CNC Turning, CNC Milling, Heat Treating
Part Dimension Envelope 600 mm x 400 mm x 100 mm
Tightest Tolerance ± .0001″
Material Used/Finish SS 15-5PH, 17-4PH (solution treated, passivated); Aluminium 7050 – T7451 (PU walkway coating per PS 2017)
In-process Testing/Inspection Dimensional Inspection, Hardness Testing, FPI, Tensile Strength Testing
Industry for Use Aerospace
Delivery Location USA
Standards Met Customer Specifications; ISO 9001 : 2008; AS 9100

Showcase: Brackets & Housings



Challenge: Development and production of a set of 9 machined rings in steel for a global locomotive manufacturer. These were the largest rings we had made so far, requiring extremely close tolerances and special painting.

Approach: Zenith located, tested and qualified a reliable local source for the material. We invested in a turning centre capable of machining 600mm dia. with close tolerances. All work-holding fixtures were custom designed and manufactured exclusively for this project. We also established a local painting source to undertake special painting which required 2500+ hours of testing.

Outcome: Successful execution of this project led to series production. Shortly after, the customer forwarded a high value inquiry for a similar machining requirement.

Loco Ring Kit

Project Highlights


Product Description Loco Ring Kit (set of 9 rings)
Machining Processes CNC Flame Cutting, CNC Turning, CNC Drilling, Face & ID Grinding
Part Dimension Envelope OD 594 mm, ID 287 mm, Thickness 75 mm
Tightest Tolerances Run out – 0.02 mm
Cylindricality – 0.02 mm
Perpendicularity – 0.02mm
Material Used S355J2+N (EN10025.2)
Special Process Customer specific paint with 2,500 hours of salt-spray testing
Industry for Use Locomotive
Delivery Location India
Standards Met Customer Specifications; ISO 9001 : 2015

eLoco Canon box kit



Challenge: Manufacture of a large set of complex brake parts for a US$ 1.2 billion global transportation major involving multiple operations, including deep-hole drilling, close tolerance holes, non-standard threads, and critical profiles.

Approach: As this was a high mix-low volume project, fixtures had to be designed and manufactured for multiple setups for each component. Special tooling and gauges were also developed. Machining was carried out on a combination of vertical machining centres, turning centres and horizontal machining centres.

Outcome: We were able to support the customer by establishing 30+ parts, over a period of three months, and begin serial production for this high-visibility, time-critical project.


Project Highlights


Product Description Brake Components
Machining Processes Bandsaw Cutting, CNC Flame Cutting, CNC Turning, CNC Milling, Deep-Hole Drilling, Protective Coating
Part Dimension Envelope 800 mm x 125 mm x 100 mm
Tightest Tolerance ± 0.01 mm
Material Used Aluminium HE 30
Special Process/Finish Anodise, Hard Anodise
Industry for Use Locomotive
Delivery Location India
Standards Met Customer Specifications; ISO 9001 : 2015

Brake Components


Asha
HEAD OFFICE

Zenith Precision Private Limited
94, 7th Main, 3rd Phase,
Peenya Industrial Area
Bangalore 560 058, India