waste reduction in engineering - a high pressure die casting process - disadvantages of die casting

Waste: materials or substances that you do not want or want (
Wikipedia: Online Encyclopedia).
For an outsider, looking at the metal casting industry, the material we waste most often seems to be time and energy --
They may be right!
In some Foundry, these are not
Replaceable resources are wasted
Not reckless, not intentional
But because their design and production methods are based on outdated production processes.
In the course of engineering in the past, paper and pencil were the most important tools owned by the foundry designer --
The development of casting is a tedious and time-consuming process.
A paper design was created;
Introduce the blue print into the mold casters-
He works with a tool manufacturer.
Die together-
Casting Machine was selected;
The process and mold layout were developed and the cost was estimated.
Quotation.
The winner of the bid allows his tool supplier to order the die steel and start with the mold design.
After completion, the mold is sent to the mold casters for the first Test.
After putting the casting into the machine, make the casting and check for defects.
It is not until this point in the process that the relevant personnel have any knowledge of the quality of the casting.
If the casting does not meet the expected standard, a change must be made.
Different process settings and slight mold correction can be made on the mold
Casting Machine immediately
However, if the first test indicates that the mold must be changed, the steel must be worn out and then welded back elsewhere, the work must be done in the facility of the tool supplier.
The mold moves back and forth between the tool manufacturer and die casting until an acceptable casting quality is reached.
Depending on the complexity and size, it may take weeks, months or years to start the time between casting design and delivering quality castings.
In addition, mold design can-and did -
Even after the start of production, these changes mean that the mold may have different designs, different ages and wear patterns, and different casting quality.
In addition to mold changes, changes in production parameters, such as die casting machine pressure, pouring speed and transformation, lubrication volume and position, solidification and cycle time, have also changed throughout the casting processThe never-
The end needs to be adjusted and improved only when casting is no longer needed.
Strive to improve casting quality and keep a huge team active, participate in process engineer, machine operator, mold maintenance and tool manufacturer, quality office, casting designer, casting processing, even assembly and material planning and processing team.
While this "engineering" was necessary for some time, today's economic reality makes it financially impossible to continue in this way --
But even so, this kind of "engineering" can be found in companies struggling in tough times.
"Production capacity of the die casting industry in the United StatesS. shrunk . . .
With the closure of factories that can't keep up with the technology. . . " Daniel L.
Twarog, president of NADCA, a letter from publisher LINKS, in February 2009, as computers entered the factory, the engineering process was changing and becoming more streamlined.
The casting is no longer drawn on paper, and the tool size is no longer required to be converted into mold drawings.
Computer-aided design is available in 3-
The size volume model allows the press of the button to pass the information and is used directly as an input to the steel processing equipment.
Model changes can be shared quickly and easily with all design departments.
The great value of computerized is the opportunity to develop, design and build almost simultaneously.
These parallel working conditions reduce development time and speed. to-
The market reached a level that was never dreamed of a few years ago.
Computerized in engineering and manufacturing processes also allow the use of more precise processing equipment in tool stores, custom mold steel and heat treatment processes that allow changes based on the following factors: the length of the production operation and the material in direct contact with melting or better heat transfer and heat flow.
One of the biggest changes is the area of process improvement.
Use MAGMASOFT (r)
Simulation software that can simulate, change, and optimize the entire casting process in a short period of time available to tool manufacturers.
Simulations made from casting models provide information on the expected quality during casting production
Before being released.
Depending on the simulation results, it is easy to make changes to the casting, gate system, mold or process parameters and quickly view the results.
Similarly, the casting can be optimized to better fill and solidify and avoid air holes;
The convection channel system can be modified to reduce the residual air volume and thus create air holes;
Develop an internal cooling layout to minimize the setting time and allow a faster production cycle, including simulations of stress calculations that can be used to predict die life, crack casting, or deformation.
Consistent use of MAGMASOFT (r)
During casting and process development, good casting and stable process were created from the first Mold test.
Further adjustments in the casting production process are only small-scale and should not change the mold or casting design at all.
The result is a design of casting, mold and process that can be used before casting is no longer needed, greatly reducing the design and production time and cost.
Reducing the time and effort in the design and production area can give the improvement team time to focus on other important tasks such as different die steel or better heat treatment to extend the effect of mold life, implement more advanced equipment to increase opportunities to cast more complex castings or save melting energy, increase automation and educate the workforce
All of this will not affect good production operation.
Committed to these changes will enhance the competitive edge of the industry and consolidate its position in the global market.
"Optimization has the potential to significantly improve the utility of the caster simulation and simulation results. " R.
Alan Miller, global computer modeling literature review, link, the increase in the speed of human work in February 2009 saves more time and effort.
Computers work hundreds of times faster than they did a few years ago, but this is a shift that humans can never replicate.
However, unlike machines, humans are intelligent and can take advantage of the improvements in these software and hardware.
Yes, it was great to leave the office, fly to the meeting, have a great lunch and stay in a nice hotel --
But it's also inefficient in most cases, wasting time and money.
Today, with the popularity of the Internet, all industries have e-commerce.
Email, ftp, phoneor web-
These technologies are entering the engineering process.
The situation disappears when people have to drive for hours to attend a short meeting or visit foreign sources overseas.
This is not to say that designers, die-diggers and tool manufacturers should not know each other --
However, at a time when the works have been reduced to commodities and can be purchased globally, individual "one-on-one" visits will be reduced or even canceled. With the ever-
Shorten the time frame for engineering, development, construction and implementation, and process travel time is no longer feasible or economical.
It takes time to do this project.
A daily suspension may endanger the delivery date.
Sending huge digital files over the Internet can take hours, but they can be used immediately for Web Conferencing once transferred.
However, some businesses still need to faceto-
Face-to-face meetings to evaluate the results, and almost all participants are wasting time and money.
But the biggest waste of time has not been discussed.
This is the buyer's hesitant decision when placing an order.
Even if quotations from casting and tooling suppliers are quoted in a timely manner, the company's finance or policy may require a second or third round of offers to try to save additional dollars here or there.
Even if the total time-to-
The market is severely restricted, and more than half of the time may be spent in the selection process, taking up to four months, resulting in insufficient time for casters and tool manufacturers to create the process, make mold and provide good casting.
The buyer's hesitation in determining the source shortens the time of the works available and may add significant costs to the process, thereby canceling any short-term costs
Long-term savings due to additional production costs and delays in time to market.
As long as a department sees only direct costs, regardless of the total cost of casting, the project will never realize its full financial potential for the company.
In conclusion, simplifying the process of high pressure die casting can still save a lot of time and energy, which will be regarded as a huge saving.
With updated computer equipment and software, travel time and costs can be greatly reduced while communication can be carried out faster and more efficiently.
Making faster decisions about sources will give engineers more time to develop more stable processes and produce better castings.
By adopting existing technology, enterprises can save irreplaceable resources.
Time and energy
While economic growth is more efficient, the most important thing is that it is more profitable.