Quality Assurance
Quality Is Not An Option.
It Is Our Process.
Every precision die casting tooling component manufactured by Vyankatesh Engineering passes through a documented 6-stage inspection sequence — from raw material certification to 100% pre-dispatch dimensional re-check. Not a sample. Every single component.
Our Approach
Quality Built Into the Process, Not Added At the End
In precision die casting tooling, a component that leaves the factory out of tolerance is a component that causes problems in the field — flash, misfire, premature failure, or a die that cannot close cleanly. Fixing quality failures after the fact is expensive and damages the production schedules of customers who rely on our components. That is why our quality assurance approach integrates inspection at every stage of manufacturing, not just at the end.
From the point at which raw material enters our facility through to the moment a component is packed for dispatch, there are defined verification gates where dimensions, hardness, surface condition, and material identity are checked and recorded. 100% of components are individually inspected — not sampled. Dimensional records, hardness data, and material certificates are retained for every order, providing full traceability from finished component back to certified raw material.
How We Inspect
Our 6-Stage Quality Process
Every component at Vyankatesh Engineering passes through these six verification stages. Each stage is documented and the records are maintained with the order.
All stock begins with certified DIN 1.2344 / AISI H-13 hot-work tool steel billet from approved mills. Each incoming batch is verified against the material test certificate (mill cert) for chemical composition and mechanical properties before it enters production.
CNC turning and milling programs are verified before each batch run. During machining, in-process gauging confirms that critical dimensions are tracking to drawing tolerance, allowing correction before the component reaches final size.
Every batch returned from our certified vacuum hardening partners is accompanied by a documented cycle record — temperature profile, soak time, and gas quench parameters. We then rigorously verify the Rockwell hardness on every batch to confirm the specified 44–48 HRC range has been achieved.
After precision grinding — the final sizing operation — every component is dimensionally inspected to drawing tolerance using CMM or precision gauges as appropriate to the geometry. Surface finish is verified against the specified Ra value.
After gas nitriding, case depth and surface hardness are verified on each batch using microhardness testing and, where specified, taper-section metallographic checks. For components with PVD hard coating, adhesion is verified before dispatch.
100% of components are re-checked dimensionally before packing. Hardness is spot-verified. Each component undergoes visual inspection for surface condition and marking. A dispatch record is generated with dimensional and hardness data, providing full traceability with the shipment.
Inspection Techniques
How We Measure and Verify
Precision Blue Matching on VMC
Prussian blue (engineer's blue) is applied to mating surfaces — parting faces, insert seats, and die register surfaces — and the components are brought together on the VMC. The contact pattern reveals high spots, gaps, and angular errors in the mating geometry that dimensional measurement alone cannot detect. This technique is used on all GDC and LPDC die parting faces and on critical insert mating faces to eliminate flash and ensure complete contact over the specified area.
CMM & Precision Gauge Measurement
Critical dimensional characteristics — cavity profiles, bore diameters, mating face geometry, positional tolerances — are verified using Coordinate Measuring Machine (CMM) measurement or calibrated precision gauges (plug gauges, ring gauges, precision bore gauges) depending on the feature type and tolerance requirement. CMM is used for complex geometries and true position verifications. Precision gauges are used for high-volume pin diameter and bore checks where speed and reliability of measurement are both required.
Rockwell Hardness Testing
Hardness testing using the Rockwell C scale (HRC) is performed on every heat treatment batch — not on a sample basis. After parts return from our certified vacuum hardening and tempering partners, a test piece from each batch is Rockwell-tested to verify that the specified hardness (typically 44–48 HRC for H-13 die steel) has been achieved uniformly. Where Rockwell B scale is more appropriate for the material condition, it is applied accordingly. Results are recorded and retained with the batch documentation.
Inspection Scope
What We Inspect — By Product Type
Inspection criteria are defined per product type based on the functional requirements of the component in a die casting application. Below is a summary of the key characteristics verified on each major product group.
Core Pins & Jet Cool Pins
- Outer diameter — full length, including any stepped sections
- Overall length and shoulder / flange dimensions
- Straightness — verified to ≤ 0.01 mm per 100 mm
- Internal bore concentricity (jet cool pins)
- Rockwell hardness — every heat treatment batch
- Surface finish — Ra verified to specification
Profile & HPDC Inserts
- Profile accuracy — all cavity surfaces to drawing
- Mating faces — flatness and fit by blue matching
- Cavity dimensions — depth, width, corner radii
- Positional accuracy — locating features and dowel holes
- Rockwell hardness — every batch
- Surface finish on cavity and parting faces
GDC & LPDC Dies
- Parting line flatness — blue matched across full contact area
- Cavity dimensions — all features per die drawing
- Runner and gate geometry
- Cooling circuit continuity and pressure integrity
- Ejector pin hole dimensions and fit
- Overall die register dimensions and guide pillar fit
Shot Sleeves
- Bore diameter — full length, at multiple planes
- Bore roundness and cylindricity
- Bore straightness
- Internal surface finish — Ra ≤ 0.4 μm
- Rockwell hardness — bore and OD surfaces
- Pour hole geometry and external seating dimensions
Every Component Ships With Full Dimensional Records
When you receive a component from Vyankatesh Engineering, it comes with a dispatch record that documents the dimensional and hardness data from final inspection. This is not a system certificate — it is actual measured data on the specific component in the box. We retain copies of these records and can reproduce them on request. For customers with incoming inspection requirements or quality system obligations, this documentation eliminates re-measurement overhead and provides a traceable basis for any field issue investigation.
- Dimensional measurement results — key characteristics per drawing
- Rockwell hardness result — furnace batch reference
- Precision shape and size verification
- Dispatch date and order reference — full audit trail
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Every component we manufacture is backed by a documented inspection record. Share your drawing or specification and we will confirm compliance with your quality requirements before production begins.