SINCE 2019 STEADY DIECASTING SOLUTIONS

3/154 ARAWALI VIHAR , RHB BHIWADI

301019
EMAIL -
STEADYDIECASTINGSOLUTIONS@GMAIL.
COM
CONTACT NO – 9549867867 ,
8750008120

WE CAN WORK FOR YOU AS A DIECASTING EXPERT

TEAM SDS
WE HAVE EARNED OUR EXPERIENCE IN TERMS OF KNOWLEDGE WHICH IS
STILL CONTINUE SO WE DON’T HAVE NUMBERS OF EXPERIENCE

BHARAT SHARMA
B.TECH( MECHANICAL), MBA ( OPERATION)
WORK WITH ROCKMAN (HARIDWAR),
SANDHAR (BAWAL), ENDURANCE ( MANESAR )
AND MAHAVIR DIE CASTERS ( MANESAR)

SAURABH YADAV

B.TECH ( MECHANICAL)
MTECH (MECHANICAL & INDUSTRIALIZATION)
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
• DIECASTING CONSULTING SERVICES ARE AVAILABLE “ ON AND
OFF SITE “
• LET US REDUCE YOUR STARTUP TIME AND SCRAP RATE .
• LET US IMPROVE YOUR PRODUCTIVITY .
• WE CAN PROVIDE TRAINING ON THE FLOOR OR IN YOUR
CLASSROOM
• WE CAN SHOW YOU HOW TO TURN YOUR PROCESS MONITORING
EQUIPMENT INTO A POWERFUL TOOL FOR QUALITY
IMPROVEMENT AND COST REDUCTION .
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 .
MACHIN HIGH I.P. CASTING GATE PLUNGE INJECTION GATE
E NAME SPEED PRESSURE( PRESSURE(KG/C AREA(CM R PISTON VELOCI Ct
(M/S) KG/CM2) M2) 2) DIA(CM) HEAD TY(M/S)
DIA(CM)
400T-3 1.47 293.7 611.435449 1.16 7 10.148.7444 0.26
4
630T-1 2.11 281.9 1127.6 2.5 8 1642.4025 0.63
6
630T-2 3.76 312.4 1249.6 3.34 8 1656.5576 0.39
630T-3 3.05 323.9 1295.6 3.2 8 16 47.885 0.57
900T 2.01 280 1120 2.41 9 1853.0314 0.40
7
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.
ACHIEVEMENT QUALITY IMPROVEMENT

POROSITY REJECTION(BRACKET) FORD COMPONENT BLOW HOLE REJECTION(COVER) HERO COMPONENT

20% 20%
18%
18% 18%

16% 16%

14% 14%
12%
12% 12%

10% 10%

8% 8%

6% 6%

4% 4%
2% 2%
2% 2%

0% 0%
BEFORE AFTER BEFORE AFTER

https://www.youtube.com/watch?v=zVUKqrGH_AI
ACHIEVEMENT QUALITY IMPROVEMENT

BLOW HOLE REJECTION(CASE MISSION) HERO COMPONENT SURPRISE BLOW HOLE REJECTION(CRANK CASE) HERO COMPONENT
20% 20%
18% 18%
16.0%
16% 16%
14% 14%
12% 12%
10% 10%
8%
8% 8%
6% 6%
4% 4%
2% 1.5% 2% 1%
0% 0%
BEFORE AFTER BEFORE AFTER
ACHIEVMENT COST SAVING

DIE COAT CONSUMTION ML/KG PLUNGER LUBE CONSUMPTION (ML/KG)

10
12
11 9

10 8

7
8
8
6

6 5 4.5
4
4 3 2.5
2
2
1

0 0
BEFORE AFTER BEFORE AFTER
ACHIEVMENT PRODUCTIVITY IMPROVEMENT

AUTOLIVE ARMATURE PRODUCTIVITY/DAY

1000 950
900

800

700

600

500 450
400

300

200

100

0
BEFORE AFTER
 ACHIEVEMENT PROCESS IMPROVEMENT
OCESS PARAMETER VALIDATION FOR ALMOST 35 COMPONENT.
LIDATION OF DEGASSING PARAMETER CHALLENGING AGAINST STAND
VALIDATION OF GRIP(HERO) COMPONENT BENEFIT REFLECT IN PLUNG
FE AND DIE LIFE.
ps://www.youtube.com/watch?v=iAEpN4NeMzo
 THANKS
FOR
YOUR VALUABLE TIME