R&D and Project Development

Established in 2019, our Design Centre has 18 employees who are experts in their fields. Through our Design Centre, we offer professional services to our customers in diverse areas such as design, Magmasoft Simulation, project planning, industrial research, andlaboratory works. Our R&D Centre helps us strengthen our technological foundation and reduce production costs, enabling us to be in the position of offering the best quality to our customers at very affordable prices.

Here at KALKANCI we recognise that technology is advancing every day and these advances are changing the parameters of production. In order to contribute to this advancement and to deliver yet more excellence to our customers in a shorter time frame, we place great importance on our R&D efforts. In this regard, the main types of service which we can offer to our customers are as follows;

Design and Simulation

This stage constitutes one of the most important stages of parts manufacturing. At this stage, moulds are designed and simulated to ensure maximum performance and durability in accordance with customer requirements. We use the most up-to-date version software to create models of the part to be produced in accordance with the casting process and customer requirements.

All the potential issues that the part being designed may encounter at the later production stage are checked, and the part is prepared for mouldability in the most optimized manner possible.

Mould design is prepared according to the product specifications. The steps in the design and simulation process are as follows;

  • Parts design focusing on weight reduction and customer quality requirements and fully ready to be moulded
  • Improving the performance of processes and products through solution-oriented principles
  • Completing designs of casting and trim moulds
  • Design of machining fixtures and all other auxiliary equipment
  • Modelling and 3D printing
  • Project management phases for pressure casting mould production

The software programs we use to execute these phases are as follows; mould design in our Design Center is carried out with “NX” and “Solidworks” software, which is easy to use and allows you to perform large and complex solid model designs. These programs, which offer successful results and alerts in the analysis and simulation phase, are very convenient in achieving detailed technical modelling, low error probability and performance.

Processing programs are prepared with NX CAM and Auton software. These software programs ensure the quality, accuracy and completeness of parts production, enabling higher levels of equipment functionality in high-quality parts production and production/inspection.

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Advanced engineering techniques are used to improve performance, resolve efficiency problems and to produce the most appropriate mould design and optimal casting parameters in parts designed using the Magmasoft simulation program. During simulation, after determining those areas in which porosity (casting cavity), shrinkage cavities, cold laps and lamination are likely to occur in actual conditions, the casting process is optimized for production through changes in the design of the runner system and through optimization of several casting parameters such as runner inflow rate, plunger stroke profile, and 3rd phase speed.

Industrial Research

As a company that provides the entire range of aluminium die casting services under one roof, we know that one of the most important steps in the product development and production process is Industrial Research. It is crucial to undertake this process, which is a must-have step to create new products, plan the origination and production processes of these products, ensure the development of products in the best and most accurate manner, and complete legal legislation, by verifying the technology generally and the functionality particularly. It is through this industrial research phase that one can, not only progress product development and improvement, but also gain different perspectives by establishing new ties with different institutions (such as universities). Our Industrial Research phase services can be set forth as follows:

  • Improvements in Industry 4.0 and digitalization technologies
  • Automation work to enable minimum production times
  • Collaboration with universities and other institutions to create new business opportunities
  • Benefiting from all the possibilities of technology, and to use new materials and technologies
  • Patent studies, beneficial model applications

Project and Planning

Products that have passed the design and simulation stages are put through the project and planning process before proceeding to the production phase. The goal of this is to determine how the particular part to be produced is likely to perform from the perspectives of raw material supply to production, from sales goals to efficiency. Important calculations such as the cost-benefit ratio, financial expenses, risk planning are carried out in this phase, and a long term, controllable production process is planned. In this context, the following works are carried out in the project and planning phase;

  • Feasibility studies
  • Management of project phases
  • Creating the scope for costs, timing and quality as well as defining goals
  • Process planning and optimization for new projects
  • Verification of design and simulation data during trials
  • Improvement during mass production to raise efficiency and quality

Materials Verification

The products are tested before delivery to our customers in accordance with the technical specification and technical drawings in the Verification Laboratory, where materials approval and comparison with alternative materials are executed by us. To achieve a fully comprehensive control, products are checked for both their chemical as well as physical properties. At KALKANCI, we execute the following checks in our Verification Laboratory;

  • • Chemical composition
  • • Mechanic properties
  • • Molten materials quality,

Performance Verification

The performance verification phase, which is part of the verification lab phase, is a very important step for products to meet standards and, if necessary, to allow for any necessary improvements to be made. In this respect, the following checks are carried out during the performance verification phase;

  • Hardness Measurement
  • Strength tests, compression and tensile tests
  • Porosity inspection using an X-Ray

Dimensional Verification

During the dimensional verification phase, which checks whether products are within the specified image tolerances, we provide the following checks;

  • CMM measurement
  • Surface quality measurement

R&D and Project Development at KALKANCI

We at KALKANCI recognise how important R&D is to being a dynamic company, thus we constantly intensify our service quality through Basic Research and Applied Research Methods. By keeping up to date with scientific and technological developments in our strategic outlook, we strive to improve both ourselves and our service quality.