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Springs Technology

Gala is Asia's largest manufacturer of Disc springs.

Three decades of rich experience forms our backbone in keeping up-to-date with latest technology to design and manufacture high performance Disc springs and Strip springs. We serve global OEMs in Power Equipments, Oil and Gas Equipments, Wind Turbines, Automotive etc. from our TS16949 certified manufacturing facilities.

Exports to Germany, Switzerland, Finland, Italy, USA, Singapore, Taiwan, China etc. contributes 60%+ of our sales. High quality, reliability and design collaboration are the key factors for us to become preferred partner of our global customers.

Your Partner for High Fatigue Springs

  • No.1
    Exporter of Springs from India
  • TS 16949
    Certified Manufacturing facilities with offices in Germany and China
  • Exports to
    25
    Countries
  • 300+
    Global Customers
  • Co-operation with
    7
    Global Research Institutes
  • 50+
    Mechanical Engineers
  • 12
    types of Surface Coatings
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Process and Technologies

Engineering

At Gala we have 30 years of experience in understanding spring material behavior. We have tie ups with global research institutes and universities in Germany and India for new product testing and new process validations.

Materials

Gala has successfully forged alliances with its suppliers of Steel, which is absolutely vital for maintaining consistency in quality and delivery. Almost 50% of raw materials are imported from leading steel mills from Europe, Brazil, Korea, etc.

Raw materials offered

  • Spring Steel Ck55, Ck60, Ck67, Ck70, Ck75, 80C6, 85C6, SWRH62A, SWRS2
  • Chrome Vanadium Steel 50CrV4 / 51CrV4
  • Precipitation Hardenable Steel 17/7Ph
  • Work Hardened Stainless Steel AISI 301, 304 and 316
  • Inconel 718 and X750
  • Grade II
  • Grade III
  • High tensile strength Piano wire
  • Oil and Tempered (OT):
    • Basic / Commercial Grade
    • Transmission / Clutch Grade
    • Valve Grade

Tool Design and Development

  • In-house tool design and development with latest CAD Software.
  • Rapid Prototyping
  • State-of-the-art CNC Wire Cut Machines for achieving surface finish upto 5 microns on cutting elements.
  • Competency of manufacturing tools from variety of materials like HSS, Carbide, Venadis, Powder Metallurgy, etc.
  • Different types of Coating and Treatments for tool elements to increase performance and achieve better edge quality.

We have developed tooling technology for shaving of edges for reducing the shear zone upto 20% of material thickness, which is close to fine blanking.

Wire Cut Machines

16 Stage Progressive Tool

Blanking and Forming

Gala is equipped with presses having capacity up to 250 tons (2500 KN). The presses are attached with automatic De-coiling. Straightening and feeding arrangements. Photo Sensors are installed for elimination mis-blanking. The punching capacity is from thickness 0.1 (0.0039") to 10 mm (0.23").

State of the art Multi-slide machines ensure we meet stringent bending tolerances as per customer's specifications.

Coiling

  • CNC Wafios Machines from Germany
  • Fully automated line with in-built SPCC software
  • Minimum Spring index 2.7
  • Suitable for coiling of Wire Diameters from 0.5 to 7 mm
  • Colour sorter and in-built camera for detection, length variation and control
  • Software iQbestspeed for automatically detecting the ideal production speed and process safety of the springs to be produced
  • High productivity upto 125 parts per minute

Heat treatment

With years of experience in handling Spring steel and Stainless steel materials, Gala has optimized heat treatment process. Based on grade of steel and end application, Gala offers various options of heat treatment.

  • Austempering
  • Case Hardening
  • Vacuum Hardening
  • Induction Hardening
  • Martensitic Hardening
  • Nitriding
  • Annealing
  • Stress Relieving

Shot Peening

  • Wheelabrator shot peening machine with magna valve ensures optimum flow of shots and consistent shot peening with residual stress induction level upto - 600 MPA resulting in high fatigue life
  • Cartridge type dust extraction system with secondary filter ensures emission level of less than 2 mg/Nm3 of outgoing air
  • Variable speed drive for wheel and belt ensures optimum control over the process

Surface Finishing

Based on 30 years of experience in surface engineering, we offer components with fine surface finish - Ra value up to 0.05 microns. This finishing process also ensures uniform edge radius for smooth assembly and movement of parts inside assembly.

Spring Grinding and Chamfering

  • Our technologically advanced CNC grinding and chamfering machine gives precise grinding with respect to parallelism, flatness and perpendicularity of the ground surface
  • High speed machines with automatic conveyor and auto loading system saves time and increases productivity
  • Servomotor is used in end grinding machine for downfeed arrangement of grinding wheel for precise grinding
  • Machine is equipped with environment friendly dust collection system
  • Online surface inspection is done after grinding

Scragging and Load Testing

Multi-station Automatic Scragging (Presetting) and Load testing machine Automatic sorting of springs with respect to Load at particular height

Inspection and Quality Control

From stringent testing like material test, micro structure and hardness test post heat treatment, dimensional accuracy, parallelism, flatness and fatigue test are a few test parameters checked at every stage. Data from raw material testing, online testing during production processes and sample testing is compiled and analysed. Any deviations are corrected using cause-effect methods so that each outgoing product is of optimum quality

  • Micro Hardness Tester
  • Online Dimension Inspection
  • Profile Projector
  • Load Testing
  • Fatigue Testing

We have developed tooling technology for shaving of edges for reducing the shear zone upto 20% of material thickness, which is close to fine blanking.

Torque Testing

Load Testing

A variety of surface treatments and coatings offered by Gala

  • Phosphating
  • Mechanical Zinc Plating (Cr 6 free)
  • Blackodising
  • Dacromating
  • Epoxy Coating
  • Nickel Chrome Plating
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Clientele

Downloads

Coil Springs

Strip and Spiral Springs for Automotive Applications

Springs Technology From Gala

Spring Assemblies for Power Equipments

Disc Springs

Bearing Series Disc Springs