Zam Zam Trading
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    Zamzam Trading Groups’ manufacturing units have integrated and technologically equipped plants to enable the working team bring out the best of the customer wants.
     
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    ACMI manufactures finished, ready to assemble Alu Alloy components. To increase the value of the product through continuous technological developments, in-house faciliZamzam Tradings of Die-Casting. Heat Treatment, Machining, Vacuum Impregnation and Leak Testing were setup. With the aim to manufacture complete range of castings, pressure die casted components also started in the year 1995. ACMI’s engineers visit customers to fully understand the component and its applications.
    Through the utilization of Advanced Computer systems, ACMI’s engineers create and develop optimum designs for dies.
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    With the company philosophy based on “Quality leads to profitability” quality of inputs has always remained the primary concern.
     
     
     
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    To meet customer requirements in respect of Tensile strength, elongation and hardness for Alu Alloy castings, Heat Treatment Facility was set up in 1993 with material handling faciliZamzam Tradings and advanced testing machines.
    ACMI invested heavily in establishing latest machining faciliZamzam Tradings comprising of Lathe machines, Milling Machines, measuring instruments, gauges etc.As a quality assurance measure, on customers requirement to supply vacuum impregnated components, subjected to pressures, vacuum impregnation plant with a capacity of 40 Tons was installed.
    Using latest in impregnation technology, cross linking mono and polyfunctional acrylates ad methacrylate sealants, made vacuum impregnation in real sense quality assurance process especially for automobile industry.
    Advanced machines manned by competent and reliable personnel made it possible to meet highest standards of quality and reliability. Components requiring leak tightness are tested with pneumatic pressures after machining.
     
     
     
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    FASTER PRODUCTION AND QUICKER DELIVERY OF PARTS
    Conventional stamping requires elaborate and expensive tooling with higher lead time. Unlike this, in Photochemical Milling / Etching Process, the photo tool is developed primarily, through a number of photographic operative steps, thereby reduction in tooling cost and higher accuracy. The photo tool costs is approximately 1/20th in comparison to conventional tool. The entire process from tooling to printing just takes few hours. The full cycle of process from drawing to finished parts can be completed in a day.
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    ACCURACY OF THE PARTS AND LIMITATIONS

    Tolerances: There are many parameters that determine the etching tolerances. As such there’s no specific benchmark/rule to calculate the etching tolerance in all cases. In general the variables that determine the etching tolerance are the type of the metal, its thickness, the number of the critical dimensions in the part and size of production run i.e. the quantity. As a thumb rule ( + ) 15% of the metal thickness is usually acceptable.
     
    RELATIONSHIP TO HOLE DIAMETER TO METAL THICKNESS (t)
    Generally the diameter of a hole can not be less than the metal thickness and the diameter should be approx. 1.25 times of the thickness of the metal.
     
    RELATIONSHIP OF LINE WIDTH TO METAL THICKNESS (t)
    In this process, the width of the metal between holes is not particularly a problem. But when a large number of openings are present in the part, generally the metal thickness between ant two consecutive openings should be 1.25 times of the metal thickness.
     
    RELATIONSHIP BETWEEN CENTER TO CENTER DIMENSIONS
    In accordance with the preparations of the production artwork, the final parts will duplicate the dimensions. The table given below gives an idea of the tolerance of center to center dimensions.
     
    C/C Dimensions (mm) Tolerances ( + )
    25.4 mm or less 0.0127 mm
    25.4 mm – 76.2 mm 0.0254 mm
    76.2 mm – 152.4 mm 0.0508 mm
    152.4 mm – 254.0 mm 0.0762 mm
     
    RELATIONSHIP OF CORNER RADIUS TO METAL THICKNESS (t)
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    Inside corner radius : The possible smallest corner of radius is approximately equal to the thickness of the metal (i.e. For a metal thickness of 0.1 mm the corner radius would be 0.1 mm.). However this can be reduced in demanding circumstances.
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    Out side corner radius : The out side corner tends to etch faster than inside and hence radius less than the metal thickness is achievable. Generally the outside radius obtainable is 0.75 times of the metal thickness (t)
     
     
    RELATIONSHIP OF BEVEL TO METAL THICKNESS (t) :
     
    Since the etchant attacks the metal vertically and laterally on both sides while etching, a small projection will be noticed on all cutting edges of the part. This sketch of the small projection is given below and it is at the center of the thickness of the matel.
     
     
    ADVANTAGES OF PHOTOCHEMICAL MILLED PARTS OVER CONVENTIONAL PARTS.
     
    » Parts produced by PCM are burr-free, strees free and are as flat as parent metal from which they are manufactured .
    » Hard metals can be etched easily without any difficulty and the molecular structure of the metal is not alter the hardness of the metal used.
    » Parts whose design make conventional stamping “impossible or uneconomical” can be produced by Photo Chemical Milling.
    » The design changes can be easily made at a low cost, while a huge cost is involved in conventional tool making.
    » Costs fro prototype productions , short production runs, even runs in the hundred of thousands of pieces are less than that in the conventional production method.
    » Lead-time from design approval to finished parts is cut down to only few days.
     
     
     
    Thus, Photo Chemical Milling saves you on toolling cost and faster deliveries of the parts, thus there is less of finished inventory.
    In short if you can design,
    we can produce.
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