The factory has more than 20 power presses ranging from 50 tons capacity to 500 tons capacity . In this operation the leaves that constitute an assembly are cold sheared to the required lengths in the shearing machine based on the drawing provided by the customers.
We have multiple stations for eye rolling machines to ensure that each and every eye is properly made and there is no oval formation in the eye.
At NX , our custom built walking beam furnace with strategically located burners ensures that spring steel of all grades and sizes are uniformly heated. These products are then cambered in a hydraulically operated eight-station drum cambering machine or quenched in a fully automated pin clamping machine to obtain thorough hardness. The subsequent tempering process develops desired levels of hardness. Transfer conveyors are used at every stage to eliminate manual handling and maintain a consistent throughput time. Various parameters of the heat treatment process are closely monitored and controlled to ensure that the desired characteristics are built into the product. The entire product range is subject to hardness testing before moving on to the post-heat treatment zone which is shot peening/stress peening, eye-reaming, scragging, assembling and packing.
After the specific total travel time, the leaves drop out at the exit of the furnace and are picked and placed on the cambering tool where the desired bend is given to the individual leaves. We have 2 lines for Quenching and Cambering. In each line quenching is done in a 40,000 litre capacity quenching oil tank complete with the conveyer and ergonomically designed cambering tool, so as to ensure the proper camber maintenance. This is done in order to avoid any re-cambering work during the assembly process.
Factory has Stress shot peening machine with more than 2 turbines and double passes for two different shot sizes to ensure maximum coverage. Two passes ensure consistent arc height on all leaves with better coverage and better compressive residual stresses at surface and depth. Online sieve shaker to keep the right shots on the hopper.
Springs are then sent for painting where the entire assembly is painted by enamel or Nitro cellulose paint by spray guns in painting booths to prevent rust in service. The factory has Paint booths with overhead conveyorized system. Both loose leafs and assemblies are painted on Conveyor.
All leaf spring individual or assemblies undergoes hardness testing to ensure uniform hardness in the desired range and dimensional tests to make sure it is within the given tolerances. The finished product, after stress peening is tested for its load rate and endurance characteristics in our in-house fatigue testing facility. The microstructure of the end product is also tested along with various other chemical tests. All light Trailer Leaf spring assemblies are cycle tested 80 thousand to 100 thousand cycles .
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