ASK Automotive is a leading manufacturer of friction products for two-wheelers in India founded in 1989. Over two decades, it has grown from a small manufacturer to a major supplier of brake assemblies, brake shoes, and other automotive parts to OEMs in India. The company aims to make its products the first choice of users. It manufactures brake shoes and other friction products through a process that includes melting aluminum alloy, die casting, trimming, lapping, inspection, and packaging. Quality is ensured through certifications and a JIT production system with zero PPM defects.

2. ASK AUTOMOTIVE PVT. LTD.
 ASK AUTOMOTIVE (P) LTD. is a leading player in the manufacturing of
Friction Products in Two-Wheeler segment founded in 1989 by Mr. K.S
RATHEE with a vision of “achieving excellence in the field of manufacturing
Automotive”.
 Over a span of two decades, ASK automotive has grown from small
manufacturer to major supplier of friction material such as brake assemblies,
brake shoe, cultch plate and aluminium casting products like panels, hubs,

3. non-automotive, crank case and engine parts etc to original equipment
manufacturers in India.
They positioned themselves as a key resource for leading OEMs With their
commitment to innovation, competence to process improvements, quality control
and customer service.
They added leading names like Hero Moto Corp., Honda Motorcycle,
Suzuki Motorcycle, Yamaha, Baja Auto, Tata Motors, Ford, TVS, Kinetic
Motor and LML to their client list.
VISION
ASK AUTOMOTIVE PVT. LTD. have a vision that, “We want all our
products to be user's first choice” keeping this in mind all ASK’s workers &
engineers work as a unit to do better than ever.
QUALITY CONTROL
ASK AUTOMOTIVE is the first company in India to be awarded QS 9000
certification of approval in its category.
The company is certified for ISO 9001:2008, QS 9000 ensuring highest level of

4. compliance to quality and defect prevention, which explains it‘s outstanding
global reputation.
The supplies are made on JIT basis
•In the JIT-based operation, day-to-day activities are driven by continuously
replenishing the customer-demand-driven finished goods inventory targets.
The delivery PPM (Part per million) to all our customers is zero
• PPM (Parts per million) is a measurement used by many customers to measure
quality performance.
• One can now control the process in order to control the quality. Quality cannot
be inspected in after the fact. It is the result of careful planning, design, and
execution.

5. PRODUCTS
BRAKE SHOE
PRESSURE DIE
CASTING
DISC PAD CRANK CASE
CLUTCH PLATE
FUEL FILTER
HEAD

6. PRODUCT
ASK AUTOMOTIVE PVT. LTD. manufactures Friction Products of Two &
Four Wheelers.
They manufacture Brake Shoes, Brake Linings, Clutch Plates, Clutch Weights,
Heavy Brake Linings, and Disc Brake Pads etc both in Asbestos, Asbestos-Free
formulations.
BRAKE SHOES
Brake shoes are the friction elements of a drum brake system.
They're made out of Aluminium alloy, curved in shape and coated with friction
material on one side.
Brake shoes can be "re-manufactured" or recycled for future use

7. Why Brake Shoes are Still Used…..?
Because drum brake systems have been around for so long, manufactures can
build them cheaply. As a result, it’s not uncommon to find a replacement set of
shoes for half the cost of a set of brake pads
While drum brake systems don’t cool as efficiently as disc brake systems, they
work great when used on the rear axles of vehicles. That’s because braking
systems in general send most of their braking effort to the front axles.
How Brake Shoes Work….?
During braking, a wheel cylinder in the drum brake system forces the brake
shoes outward and against the spinning brake drums
This creates friction, slowing the drum and as a result, the vehicle

9. BRAKE SHOES
MATERIAL:-
The material for product is heat treatable Aluminium Alloy which used as a raw
material for brake shoe manufacturing. The typical alloying elements are copper,
magnesium, manganese, silicon, tin and zinc.
Frictional material offers the following benefits:
High and stable friction levels
Very good fade resistance
Increased life time
Significant improvement in driving comfort

10. MANUFACTURING PROCESS
RAW MATERIAL
MELTING OF RAW MATERIAL
DIE CASTING
FETTLING & TRIMMING
LAPPING
CAVITY-WISE SEGREGATION
VISUAL INSPECTION
WEIGHT DETERMINATION
PACKAGING REJECTION
Aluminium
Alloy
AT 640-680deg-cent.
Temp.
Die Temp.
200-250oc
Extra Material
Removal
Defect detection
manually
TESTING
Die Division

11. Raw Material
Aluminium alloy is used for casting. The material for product is heat treatable.
Aluminium Alloy which used as a raw material for brake shoe manufacturing.
The typical alloying elements are copper, magnesium, manganese, silicon, tin and
zinc.

12. Our frictional material offers the following benefits:
High and stable friction levels
Very good fade resistance
Increased life time
Significant improvement in driving comfort
Melting of Raw Material
 Electric heating chamber with electricity as the heat source for achieving very
high temperatures to melt and alloy metals and refractories.
The electricity has no electrochemical effect on the metal but simply heats it.
 Aluminium alloy get melted on the temperature between 640-680oc. The
melting of aluminium alloy basically occurs at 650oc.
 Electric furnaces generally are either arc furnaces or induction furnaces.

13. Electric furnaces are used to produce almost all the special alloys required by
the chemical, automotive, aircraft, machine-tool, transportation, and food-
processing industries.
Electric furnaces also are employed, exclusively, by mini-mills, small plants
using scrap charges to produce reinforcing bars, merchant bars (e.g., angles and
channels), and structural sections.
Electrical furnace

14. Die Casting
Die casting is a versatile process for producing engineered metal parts by
forcing molten metal under high pressure into reusable steel moulds.
The moulds, called dies, can be designed to produce complex shapes with a high
degree of accuracy and repeatability.
Die casting is an efficient, economical process offering a broader range of
shapes and components than any other manufacturing technique.
 Parts have long service life and may be designed to complement the visual
appeal of the surrounding part.
Die castings are among the highest volume, mass-produced items manufactured
by the metalworking industry.

15. S. NO. PARAMETER VALUE
1. Die opening time 5sec
2. Pump pressure 90-120 kg/cm2
3. Die temperature 200-250oc
4. N2 pressure 60-80 kg/cm2
Machine Parameter

16. Designers can gain a number of advantages and benefits by specifying die cast
parts. Some of the benefits are mentioned below-
•High-speed production
Die casting provides complex shapes within closer tolerances than many other
mass production processes.
•Dimensional accuracy and stability
Die casting produces parts that are durable and dimensionally stable, while
maintaining close tolerances.
•Strength and weight
Die cast parts are stronger than plastic injection mouldings having the same
dimensions.
•Multiple finishing techniques - Die cast parts can be produced with smooth or
textured surfaces.
•Simplified Assembly - Die castings provide integral fastening elements, such as
bosses and studs.

17. Fettling & Trimming
The method of fettling must be taken into account at the initial casting design
stage, so that the process is fast and efficient.
The metal removal is often achieved using manual cutting or
grinding. However, more emphasis is being placed on automatic fettling, whereby
the casting is placed in a machine programmed to remove materials from specific
areas.
If flash cannot be reliably avoided it is often the best plan to use a press trim
tool to remove both the runners and the flash simultaneously.
Press trimming is a metal shearing operation; therefore the casting must have
sufficient strength and rigidity to withstand deformation in the trimming
operation.
A press trim tool normally costs around 10% of the cost of the associated die.

18. Press trim tools are normally manually operated, but when automatic die-casting
is used with robotic extraction, the robot frequently places the extracted shot on
the press trim tool and the press is started automatically.
The speed of the press trimming operation is not normally affected very much
by the casting design. However its reliability in achieving complete flash removal
is radically improved by good parting line design.
The cost of trimming operations for Aluminium alloys is the same as for other
die-casting alloys.
For the removal of the extra metal several methods are used-
• With chipping hammer- It is particularly used to remove the flash from the
product.

19. •With file- File is used to removal the material such as from edges, body width ,
pad side etc.
•Bench-vice is used as a holding device.

20. With fettling machine- This method is used for achieving higher accuracy in
product.
Fettling Machine

21. Lapping & Grinding
Lapping is the removal of material to produce a smooth, flat, unpolished
surface.
 Lapping removes subsurface damage caused by sawing or grinding and
produces the required thickness and flatness. Although the lapping process is less
damaging than grinding.
There are two regimes of lapping: free abrasive lapping and fixed abrasive
lapping-
• Free abrasive lapping is accurate because of the rigid lapping surface which can
be tailored to suit a particular material.
•Fixed Abrasive Lapping is when an abrasive particle in bonded to a substrate as
with abrasive lapping films and SiC papers.
Grinding can be defined as the rapid removal of material from a sample either to
reduce it to a suitable size or to remove large irregularities from the surface.
 The grinding wheel or plate typically rotates at a high speed.

22. Grinding is quick and relatively easy process but can cause deep subsurface
damage in delicate materials.
Typically grinding is applied to hard metals such as high carbon steels where
rapid removal is essential and subsurface damage is not a critical parameter.
Belt Grinder

23. Inspection & Final Testing
Based on the specific needs throughout the manufacturing process, there are
following inspections through which the product passes-
Pre-Production Inspections
Intertek group inspects raw materials and components before production begins.
They can provide the factory with the technical advice necessary to improve
product quality and to minimize the chance of defects during production.
During Production Inspections
During Production Inspections are ideal for shipments of substantial quantities;
product lines with continuous production; strict requirements for on-time
shipments; and as a follow-up if poor results were found during Pre-Production
Inspection.
Visual Inspections
Visual Inspection is carried out to detect the defects which can be arise because of
bad die casting or during finishing process. The defects which are found in the
visual inspection are-

24. •Pin Deep
•Bend
•Chip off
•Drill out
•Blow Hole
•Non-Filling
•Catching
•Grinder Cut
•Pin Deep
During the process of casting , when melted material get forced into the cold
chamber through the pin situated into the die a part of pin due to the high
temperature of the material may get stuck into the casted product because of
which the defect into the product occurs.

25. •Bend
During casting, fettling or lapping process brake shoe may get bend which is got
inspected into the gauge.
•Grinder cut
During the process of lapping on belt grinder machine of body width & pad side
width of brake shoe may get cut wrongly. This defect is getting inspected in visual
inspection.

26. •Drill Cut
This defect occurs during the drilling process.
Final Random Inspections
Final Random Inspections can begin only after production through a statistical
method set by industry standards, inspection is done of a sample products to
verify product safety, quantity, workmanship, function, colour, size, packing, and
more.