Production process improvement in the die casting industry


 

Process improvement, in the zinc die casting industry as well as in many other manufacturing sectors, consists of a series of actions undertaken to enhance production times, to reduce costs and, consequently, to obtain results that satisfy client’s requests in terms of timing and performance. 

by Arianna Piersigilli November 20, 2018

Simulation for HPDC: shrinkage porosity case study

by Marcello Cazzaniga August 28, 2018

Simulation for HPDC: shrinkage porosity case study


In this post we are going to explore a case study dedicated to the improvement of mechanical characteristics, by reducing shrinkage porosity in a component for building sector. This post is part of a series in which we explain the importance of simulation for HPDC (High Pressure Die Casting) through the presentation of real life cases.

by Marcello Cazzaniga August 28, 2018

Dimensional measurement: production control and reverse engineering

by Marcello Cazzaniga July 26, 2017

Dimensional measurement: production control and reverse engineering


Having a metrology room inside of die casting plant, focused on the dimensional control of the components, assures the requested dimensional quality of production in order to reach customer's needs in terms of lead time and minimize risks.

by Marcello Cazzaniga July 26, 2017

Die casting simulation for shrinkage porosity prediction

by Stefano Polli December 16, 2016

Die casting simulation for shrinkage porosity prediction

In zinc alloy a faster casting method has been developed, which makes it possible to produce castings with specific features, suitable for the manufacturing of automotive parts, large and small household appliances components and hydrothermal systems.

In die casting processes, the mould filling phase is highly critical because defects such as air entrapment and shrinkage porosity might occur. In the mould, gas is compressed by the melt being poured and discharged outside through the vent. Choosing the proper die casting method is the best way to avoid such defects due to pressure and  air entrapment.

To predict shrinkage porosity and other defects, simulation is increasingly used nowadays, as these software require less development cost and time than experiments. Only some specific simulation programs, however, take into consideration the effect of back pressure in the cavity in die-casting.

In this article we are going to discuss:

- What is shrinkage porosity
- Causes of the defect
- How to avoid it with simulation

by Stefano Polli December 16, 2016

How to reduce scrap in die casting process

by Davide Gioletta October 25, 2016

How to reduce scrap in die casting process


 

Reducing scrap could be your next way to cut costs in die casting process. Saving allows you to invest in research and development, maybe right to find new ways to reduce scraps: in a sort of golden circle which allow your company to be more performing. In this case using the right methodology and the right tools the solution could be suitable for your company.

First of all the most important thing is to analyze the situation, working on the causes of scrap: both in terms of new projects, than about existing components or products.

This is the initial turn point.

For each of these tasks you can distinguish 2 different phases: engineering phase and process phase.

by Davide Gioletta October 25, 2016