About Us

OBJECTIVE THOUGHT

IN EVERY DIE CASTING PLANT , THERE IS USUALLY ONE PERSON; WE'LL CALL HIM MASTER, WHO CAN ALMOST ALWAYS MAKE A GOOD CASTING. THE PROBLEM IS THE PRODUCTIVITY OF THE OPERATION WAS LIMITED BY THE NUMBER OF HOURS HE CAN WORK. AND WHAT IF HE TAKE A VACATION? MASTER IS THE "BLACK ART" DIE CASTER. HE COULD PERSUADE THE PROCESS TO PRODUCE AN ACCEPTABLE CASTING BY TWISTING KNOBS AND VARIOUS DIE SPRAY TECHNIQUES KNOWN ONLY TO HIM. EVENTUALLY HE WOULD TRAIN AN OPERATOR IN THE TECHNIQUE AND FOR A FEW HOURS THEY COULD CONTINUE TO PRODUCE GOOD CASTINGS. THEN THE NEXT SHIFT WOULD ARRIVE AND A NEW RECIPE WOULD BE INTRODUCED AND THE QUALITY WOULD CHANGE, USUALLY WORSE. WHEN YOU WILL IN A CRISIS FOR PARTS, MASTER WOULD BE CALLED BACK ON OVERTIME TO "FIX" THE PROBLEM, AFTER A FEW MINUTES OR HOURS, THE PROCESS WOULD PRODUCE GOOD CASTINGS AGAIN, HE WOULD TRAIN THAT OPERATOR AND YOU WERE GOOD UNTIL THE NEXT SHIFT CHANGE.

ALMOST DIE-CASTING PLANT RUNNING WITH THIS THEORY CALLED “MASTER” AND WE HAVE TO KILL MASTER .

SDS LEADING TO ENGINEERING AND CONSULTING TO THE DIECASTING INDUSTRY

SDS HELPED PRODUCE NUMBER OF SUCCESSFUL ALUMINIUM DIECASTING . WE HAVE ASSISTED DIECASTING BUSINESS OWNERS , MANAGERS , ENGINEERS AND OPERATORS IN REDUCING COSTS , WHILE IMPROVING PRODUCTIVITY , PROFITS AND CUSTOMER SATISFACTION . CHANCES ARE YOU OWN ANY KIND OF DIECASTING , WE HELPED DEVELOP AND PRODUCE . SDS “HANDS ON” WHEN IT COMES TO SOLVING PROBLEMS AND TRAINING .

SDS PROVIDE HIGH PRESSURE DIECASTING CONSULTING AND ENGINEERING SERVICES TO THE GLOBAL DIECASTING MARKET

CONSULTING

TRAINING TO EMPLOYEES

  • Die Cast Gating
  • Process Control
  • SPC (Statistical Process Control)
  • Die Casting Defects
  • Metal melting and handling
  • Machine hydraulics and pneumatics
  • PQ^2
  • D.O.E., (Design of Experiments)

PROBLEM SOLVING THIS CAN FALL INTO SEVERAL CATEGORIES

  • SCRAP REDUCTION THROUGH PQ² ANAYSIS , OBJECTIVE WOULD BE TO “CUT IN HALF” .
  • THE SDS WORKING WITH YOUR STAFF AS A TEAM CAN PERFORM THE EVOLUTIONS , THIS WILL HELP REINFORCE BOTH THE SIGNS APPLIED TO THE SOLUTION AS WELL AS TEAM CULTURE NECESSARY FOR LONG TERM GROWTH AND SUCCESS .

PROCESS CONTROL IMPLEMENTATION AND TRAINING

USING YOUR MONITORING EQUIPMENT , WE WILL DEMONSTRATE THE BENEFIT OF USING PROCESS MONITORING TO IDENTIFY THE “KEY PROCESS PARAMETERS” . ONCE THIS IS ESTABLISHED , WE WILL TRAIN YOUR DESIGNATED PERSONNEL , SUCH AS DIECAST SUPEVISORS , SETUP , TOOLING ENGINEERS , PROCESS ENGINEERS AND MAINTENANCE PERSONNEL IN THE USE AND INTERPRETATION OF THE DATA .

PROCESS IMPROVEMENT BY USING LATEST TECHNOLOGY OR EQUIPMENT

  • WE WILL UPDATE YOU AND YOUR STAFF WITH THE LATEST PROCESS CONTROL, TOOL ENGINEERING, AND DESIGN TECHNIQUES.
  • ALLOY TEMPERATURE DURING INJECTION
  • CAVITY FILL TIME, EXPRESSED IN MILLISECONDS
  • DIE TEMPERATURE MEASURED IN THE DIE CAVITY AREA
  • GATE VELOCITY, EXPRESSED IN FEET, METERS OR INCHES PER SECOND
  • IN THE COLD CHAMBER PROCESS, CRITICAL SLOW SHOT VELOCITY EXPRESSED IN METERS OR INCHES PER SECOND
  • TRANSITION POINT FROM SLOW TO FAST SHOT SPEED.
  • CAVITY PRESSURE DURING INTENSIFICATION EXPRESSED IN P.S.I. OR KG/CM
  • HYDRAULIC INTENSIFICATION PRESSURE, EXPRESSED IN P.S.I. OR KG/CM
  • RISE TIME TO INTENSIFICATION EXPRESSED IN MILLISECONDS
  • CONTROLLING THE LOCKING FORCE ON THE DIE, EXPRESSED IN TONNAGE

CASTING DESIGN FOR YOU AND YOUR CUSTOMER

  • SDS CAN PROVIDE DESIGN ASSISTANT TO YOU AND YOUR CUSTOMER BY PROVIDING THIS SERVICE EARLY IN THE PRODUCT LIFECYCLE YOU CAN ELIMINATE MANY PROBLEMS AND REDUCE SCRAP RATE COST BY INAPPROPRIATE CASTING DESIGN .
  • THE SDS PROVIDE THE TRAINING MATERIAL AND COURSE MATERIAL WHICH CAN BE CUSTOMISE TO ADDRESS SPECIFIC PROBLEMS KNOWN TO BE COMMON TO A SPECIFIC CUSTOMER .

BEING OUR CUSTOMER WHY YOU SHOULD OPT US

  • SDS BELIEVES DIECASTING MUST RUN ON SCIENTIFIC PRINCIPLES
  • SDS BELIEVES TO PRODUCE CASTING THROUGH SCIENTIFIC VALIDATION AND STANDARDIZATION , NOT BY BLACK ART .
  • SDS BELIEVES TO EDUCATE DIECASTING STAFF LIKE SUPERVISORS , ENGINEERS , MANAGERS , CEO AND OWNERS .
  • SDS BELIEVES IN CUSTOMER DELIGHTNESS THROUGH QUALITY , PRODUCTIVITY AND PROCESS IMPROVEMENT.
  • SDS BELIEVES SAFETY AS PRIORITY AT WORK PLACES.

Scope of work:

  • New plant development.
  • New product development.
  • Die modification.
  • Process parameter validation.
  • Alloy selection.
  • Rejection or defect control.
  • One training per month.
  • Machine selection.
  • On site training
  • Casting defect control.
  • Metal treatment process validation,
  • a)Cleaning of molten metal. ( Type of flux, method of cleaning )
  • b)Degassing of molten metal. ( Type of degassing, Flux use, rotor size, rotor rpm,n2 lpm,etc)
  • c)Holding of molten metal.
  • d)Pouring of molten metal.
  • Ensure availability of skilled Operator, Engineer,
  • Manager, Plant head, and CEO.
  • Die parameter validation,

a)Casting gate area.

b)Plunger size.

c)Overflow volume.

d)Overflow size.

e)Overflow position.

f)Overflow gate area.

g)Air vents size.

h)Runner volume.

i)Runner size.

  • Biscuit thickness validation.
  • Machine parameter validation,
  • a)High speed.

    b)Low speed.

    c)High speed length.

    d)Intensification pressure.

    e)Pressure build time. ( P-Rise )

    f)Fast shot charging pressure.

    g)Intensification charging pressure.

    h)Injection delay.

    i)Spray time.

    j)Ladling time.

    k)Solidification or cooling time.

    Target:

    ACHIEVEMENT PROCESS IMPROVEMENT