FORGINGS
KEL has in house forging capability and makes 90% of all its forging requirement inhouse through its 1300-ton National Press | 1 ton Hammer | 2 ton hammer.
Equipped with induction heaters, 2 normalizing furnaces, 2 shot blasting furnaces
MACHINERY
Gears & Shaft Cutting
KEL specialises in the art of precise gear manufacturing. Over decades, we have learnt the nuances that make a gear perfect in order to ensure the required torques are delivered noiselessly, and in a cost efficient manner. From Turning, to hobbing, shaving, rolling, broaching, pointing, rounding, swaging, shaping; KEL has capability of all the soft operations. It also finished the gear through hard turning or OD/ID grinding operations. We realise and admire the criticality a gear requires and are processes, machinery & systems are driven towards ensuring the same.
GEAR CUTTING MACHINERY (SOFT)
HEAT TREATMENT
KEL has an in house heat treatment shop capable of hardening the gears & shafts through case carbeurising, carbon nitirding and even induction hardening & sursulf treatments. The HT shop, powered by 3 SQF and a SCADA controlled CGC furnace ensures the required hardness & case depth for the gears. There is effectively designed loading plates and special technologies available including plug quenching, the distortion of critical components like shifter sleeves can be controlled accurately. The HT shop is equipped with a metallurgical lab (Spectrometer, Image analyser ,micro hardness tester), where every component from each batch is cut, checked & recorded for its accuracy.
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3 sealed quench furnaces (Unitherm make).
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1 continuous gas carburizing furnace (high temp)
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2 induction hardening (Inductotherm make)
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5 tempering furnaces
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2 shotblasting furnaces
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1 plug quenching furnace (Inductotherm make)
Processes include case carburizing & hardning, carbo-nitriding, sursulf-nitriding, induction hardening. 100% of our components are heat treated in house.
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Metlab equipment
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Rockwell hardness tester & Micro hardness tester
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Spectrometer
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Image analyser
PRECISION MACHINING
Special VMC/HMC capabilities include precision milling, drilling, tapping and capable of manufacturing c and aluminium housings/covers for gearboxes in house.
KEL is proud to have high precision machines for the same including Hellar, Chiron & Jyoti VMC/HMCs In other machines capable of performing accurate similar operations
ASSEMBLY CAPABILITEIS
KEL not only makes its gears & shafts, it also machines the housings & finally delivers a completely assembled gearbox or rigid axle to its customers. This unique capability involves development & management of all sub suppliers of child parts other than machined parts such as levers, bearings, inserts, jaws, housings etc. KEL has end of line testing equipment which checks and records for noise, slippage, leakage as well as smooth functioning every gearbox before going to the customer.
Various OEMS including TATA, Piaggio, Mahindra, Ashok Leyland, Aixam, Kinetic Green have trusted KEL to develop & manufacture this critical assembly as a bought out item for them.
The assembly capabilities have recently diversified itself into also making rigid axles & transaxles for electric commercial vehicles.
BODY SHOP CAPABILITIES
PRESS SHOP
KEL has a large press shop consisting of several machines from 60 ton to 200 tons presses. These are used for making press parts required for 2 wheeler/3 wheeler vehicle body parts, chassis parts, side panels, or wheel rims or axle and other such parts.
WELD SHOP
KEL also has a weld shop that can perform tig welding, mig welding, CO2 welding and spot welding. KEL’s skilled operators successfully weld various parts such as rigid axles, 2 & 3 wheeler chassis, chain covers. Recently KEL has expanded to make chassis for the E-luna and other electric vehicle scooters. It has also diversified into making rigid axles for electric 3 wheelers.
PAINTING & PLATING SHOP
KEL has a fully equipped painting facility including powder coating, liquid painting & CED with their required pre-treatment & baking processes That are capable of painting high quality parts in large volume to the desired salt spray tests.
KEL also has a zinc plating facility capable for yellow passivation as well as hard chrome plating to maintain surface hardness.
