Copper Parts Manufacturing at BMS

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We are Contract-Manufacturers of specialised in Copper Component Producing Technology. One wing of our unit is solely devoted to Copper.

This wing processes Custom-Built Copper Parts, Components & Sub-Assemblies for OEM Electrical Industry with Specialized Focus on Automotive, Marine, Power Transmission (HT/LT) & Consumer Electrical Industries.

We specialize in Design/Development & Production as per Clients' Specifications.

Servicing reputed OEM brand Owner Electrical clientele in Europe, USA, New Zealand & Australia, we have mastered the Art of various Processing Technologies to produce Copper Components in all forms of purity right up to the electrolytic type which is the purest form of copper (used as electrical conduction)

Our Professional Systems & Procedures of Design, Development, & Manufacturing to ensure Cost Effective Quality Copper Products are sequentially mentioned below.

OUR ENGINEERING CAPABILITIES, PRODUCTS & INDUSTRIES SERVED

COPPER MATERIALS, MANUFACTURING ENGINEERING & TECHNOLOGIES

MANUFACTURING INFRASTRUCTURE FOR COPPER COMPONENTS

QUALITY PROCEDURES

INTRICATE PRODUCTS DEVELOPED FOR INTERNATIONAL CLIENTS

	Development & Production of High Precision Copper components as per Custom Design, with Intricate Shapes & Profiles having close tolerances & Accuracy.

	Expertise in Manufacturing Engineering with subjective Knowledge of Standards, Materials, Manufacturing Processes & Tool Making, to produce Copper components for Electrical, High/Low Tension Power Transmission & Electronics

	Expertise in 3D & 2D Software enable us to achieve successful results.

	Controlling Wastage in Raw material by Dexterously Designed Tooling & Process Controls enable us to get optimized material utilization.

	Providing Total Solution inclusive of Post-manufacturing Processes like Surface Finishing, Coating / Plating, Heat Treatment & Other allied processes like Soldering, Silver soldering, Brazing, etc.

	Thorough Understanding of Client’s Design specifications & functional requirements of the end product for Electrical & Electronic Applications

	Reverse Engineering Services & Assistance in carrying out Design Activities / Design Up-gradation & adopting suitable manufacturing processes to achieve Clients desired cost effective solutions.

	Expertise in fault finding and research capability, for applying corrective action.

Copper Components for Rotary Switches, Control Panels & Heavy Duty Current Carrying Applications like Power Transformers, Switch gears etc. like :

	CONTACTS			FUSE HOLDERS
	BUS BARS			FASTENERS / WASHERS
	TERMINALS			CLIPS
	CONNECTORS			SPRINGS & WIRE FORMS
	RELAYS			COPPER PIPES & FITTINGS
	COMMUTATORS			CUSTOM MADE COPPER COMPONENTS & ASSEMBLIES AS PER CLIENTS SPECIFICATIONS
	ROTOR BAR

ELECTRICAL SWITCH GEARS

& CONTACTORS

ELECTRICAL HIGH/LOW TENSION

POWER TRANSMISSION

AUTOMOTIVE ELECTRICALS

MARINE ELECTRICALS

ELECTRONICS

HARDWARE & FASTENERS

REFRIGERATION &

TEMPRATURE CONTROL

We use Copper, Copper Alloys & other Non-ferrous materials in various forms such as Sheets, Strips / Coils, Rods / Flats & Sections, Forging & Castings etc as follows


	99.9 % Purity Electrolytic Copper

	Commercial Grade Copper

	Specialty Copper Alloys like Beryllium Copper ,Chromium Copper, Zirconium Copper , Tellurium Copper etc per international standards

	Traditional Copper Alloys like Brass, Bronze, Gun Metal etc

	Other Metallurgical variants as per international Standards

We look at Copper from the microscopic levels like grain homogeneity & orientation, while manufacturing of components having extreme close tolerances and finishes:

FORGINGS in closed and open dies : Achieving Odd Shapes & Profiles of Copper Components is our speciality

UPSET FORGINGS : Achieving high ratio of flared Heads coupled with high eccentricity and combination of multiple profiles on the heads of Copper Components is our specialty

Precision Cutting & Forming Complex Profiles of Copper components with focus on electrical applications like Contact Snap Locking, Smooth Surfaced Contact Domes at Controlled Distances etc is our specialty

Ability to Machine Complex Profiles, while Maintaining Extremely Close Tolerances & very High Finish.

We are experts at Silver Soldering, / Brazing / Soldering etc. to ensure good Capillary Action & without any Porosity to optimize Electric conductivity

We are vertically integrated with a team of various Associated ISO 9000 accredited Manufacturing Units, each specializing in a specific field of production Activity to ensure optimum quality with on time deliveries:

equipped with CNC Turning and

Milling centers, SPMs, & Automats like Traubs, Conventional Machines like Lathe & Drilling, Grinding, Milling, Roll Threading Machines, Ultrasonic Cleaning & Vibrator Deburring. Tool Room & Auxiliary equipment facilities for Attachments & Fixtures.

equipped with Shearing Machines,

Power presses, Hydraulic Power Presses, Press Brakes, CNC Turret Press, Vibrator Deburing Machines & Fully Equipped Tool room with sophisticated Measuring Instruments.

equipped with Induction Heating Facilities for small

Upset forgings, Up-setters for head forming operations, Furnaces with Automatic Temperature Controllers, Power Press (Pneumatic Hydraulic & Mechanical) ,Friction Drop Hammers, Fully Equipped Die Shop & Tool Room.

equipped with advanced Equipments

We have access

to facilites for Specialized Heat Treatments like Nitrogen Annealing, Precipitate Hardening, Homogenizing etc

have access to facilites for surface treatments & Plating like Chrome, Gold, Silver, Tin, Cadmium, Chrome, Nickel / Electroless Nickel, acid washing etc. These units have Automatic Electronic controlled equipments to regulate plating thickness.

includes Shophisticated Measuring

Equipments like Surface table, digital height gauge, Digital Precision Micrometers, Profile Projectors, Surface finish measuring gauge, sign bars, bench centers and all other standard Inspection Equipments.

having international accredition & equipped with advanced

facilities like Computerised Spectrometer for chemical analysis, 3D Coordinate Measuring Machines (CMM), Tensile and compressive load test machines, NDT set up, etc.

	Inspection and identification of the material at Electrolytic forming stage of Ingot to ensure that the defective portions of the Ingots are discarded correctly.

	Chemical analysis for Purity, ensuring the composition as per required grade.

	Ultrasonic tests of Extrusion Bars & Rods

	Checks for Work Hardening of Rolled Sheet

	1st piece Inspection.

	Patrol inspection (SPC for critical close controlled dimensions),

	Final Inspection by SQC Method

	Checks for Work Hardening of Rolled Sheet

	Inspection for folds and cracks

	Inspection of grain directions of formed profiles. (1st piece for corrective action).

	Testing of Ultimate tensile/shear strengths to ensure Specifications.

	Microscopic Inspection of sectioned pieces for Electric Conductive and Current Flow Tests for Joints

Brass Bronze & Traditional Copper Alloys

We have developed various intricate Copper items requiring sophisticated machines for processing and have operators with good skills. Some of the products are listed below:

	Slender 100mm Deep Milled slits compared to Ø 35 mm and heavy thickness of the Wall

	Fine slit Milling with many inline slits, alternate slits being in opposite directions.

	Involves Precision Turning and Eccentric Milling using Carbide Tipped Milling Cutters.

	Required constant monitoring with special purpose dedicated gauges

	Co-ordinate drilling required due to precision positioning of holes

	Milling of the Slit done at the end of all operations, to eliminate dimensional variations due to springing open of the slit.

	Deburring the Cross hole that is intersecting the Milled Slit required high skills.

	8 Arms Contact required development of dedicated Collapsible inserts form holder for processing

	The intricate shape calls for Skills & care to eject the component from the tool.

	The Operation is done on a Hydraulic press, with variable controlled speeds, that are required at various stages of the forming cycle.

	Material saving is achieved by designing the Blanking Tool to match intricate strip lay-out consisting interlocked fingers.

	Forming the 3 mm thick sheet with 1.5 mm slit & Narrow U Bend of critical Inner radius without springing back, called for a tool of unique design

	Slitting was done after complete forming to avoid distortion.

	Deburring of the slits was done by Ultra-sonic cleaning, to avoid formation of inside burr.

Switching Contacts with Smooth Dome Profiles

	Forming accurately Projected Domes of exactly equal heights at the extreme edges, without the plate bending, is a specialty in tool designing.

	Precision Shearing free of burrs was also a specialty in tool design

	2,5 mm Thick Main Connector required Fine Blanking Tools & specialized Process.

	Critical Bending of the Notched End required extra care & presicion

	Pressure spin riveting for Joining the thin Copper Lug to the thick Thick Main Connector to ensure solid joint without any air gap.

Heavy-duty Copper contactors for Battery Switches

	Forged Contact, with large eccentric upset wherein 7mm Ø bar is Spread to 452 sq mm at 25mm eccentricity.

	By our know-how we innovated a unique process to achieve minimum waste, thus maximum cost saving. Forming this profile by conventional Head Forging would result in huge copper wastage due to large one sided Flanged Head.

	Flat bar forged to form flat tang of 8mm thickness with Forged bend to required angle.

	Complex milling fixtures were made to ensure high precision squareness and flatness at the desired angle with respect to the rod

Forged Heavy Terminals Bolt weighing 1 kg

	1.25” bar upsetted to 2.5” Ø x 3/8 thick flattened top.

	Then precision Machined to achieve various Diameter on the Bolt Stem.

	Silver soldering of 3/8” UNC studs into 3mm thick copper Bus bars.

	Capillary action of the silver solder through the entire thread length maintained to achieve Sturdy Joint while ensuring Perfect Conductivity.

	Silver soldering of 3/8” UNC studs into Tapped Holes of the 6 and 10mm thick copper Bus bars.

	Capillary action of the silver solder through the entire thread lengths maintained to achieve Sturdy Joint while ensuring Perfect Conductivity (To Carry 400 & 800 amps capacity)

	Large & Thick Copper Flats are precision machined to flatness, parallelism and thickness within 0.02mm T.I.R

	Silver brazing the tang into a rod involving complex fixturing to ensure that:

		Alignment is within 0.05mm T.I.R.

		The brazing through capillary action covers the whole joint area giving strength and excellent conductivity. (Being conductors for very heavy current flows)

	Co-ordinate drilling after brazing to ensure accuracies


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