5 Case Studies: watch Bruschi die casting videos
We made some new videos that show our productive process and the characteristics of some components.
Products have been chosen on the basis of different principles: we privileged variety, selecting components that are produced for different sectors and complexity, in order to communicate our expertise and competence in satisfying the client's requests.
Here the list of the videos:
- Die casting for household appliances: coffee machines
- Die casting for automotive: electronic steering wheel lock
- Die casting for automotive: sunroofs
- Die casting for building industry: windows and doors
- Die casting for household appliances: hinge for washing machines
Let's give the floor to our experts.
Die casting for household appliances: coffee machines
In this video we show the production of a component for coffee machines and we describe the technical solutions implemented to obtain a perfect chrome finish.
This product is the bottom section of a coffee machine for the consumer market. It is an aesthetic component that comes into view and in contact with the end customer: for this reason there are specific technical and quality aspects to consider. During analysis stage, indeed, we have faced technical and process difficulties caused by the particular shape of the component, which could invalidate the requested standards thus reducing the quality of chrome finish.
It is exactly the particular geometry of the piece that does not allow the working of the internal surface and it is for this reason that, after careful analyses of the production process and considerations on the shape of the component, we decided to obtain a surface that was suitable for chroming process already after casting phase.
In order to reach this aim we have undertaken virtual and physical prototyping and simulation activities that have allowed the definition of optimal parameters for the production of the component. Thanks to simulation and prototyping we have identified two properties on which we have specifically focused our attention: roughness and surface quality. To achieve the expected result already during casting stage we tried to take the most out of production parameters. The lapping of the mold has been the chosen solution to obtain surface roughness already during casting phase; simulation and tests during production phase allowed us to modify the mold in order to obtain the requested surface quality and standards.
The adoption of these technical solutions and the modified parameters have therefore allowed us to obtain a product suitable for polishing and chroming treatments.
The polishing stage is carried out on still rough pieces, whose external surface is smoothed so that the subsequent chroming process has a good result. The next stage is indeed chroming phase. Chroming process is an aesthetic galvanic process that gives to the die cast a charming and protective aspect: the chrome surface, indeed, protects against corrosion. It is a process composed of various passages where the products are immersed in aligned tanks to receive sequentially processes of degreasing, copper plating, nickel plating and chromium plating. It is this final stage that gives, thanks to the extremely brilliant aspect, an important added value to the component, making it a distinctive element of coffee machines.
Die casting for automotive: electronic steering lock
In this video we present an automotive component whose mold has been designed in an unconventional way and on which it has been introduced an automatic threading system.
This component of the electronic steering lock has required an unconventional mold design because it is characterized by a complex shape. Indeed, the inner section of the product, which is designed to hold an electronic card and to contain sliding parts, has caused the main difficulties in mold design. Therefore, the structural complexity of the component, connected with the production process, has determined the necessity to obtain a considerable level of accuracy during mass production.
Considering that the product is designed to internally contain an electronic card and further functional elements, it is necessary the total lack of die casting defects (for example burrs) that could compromise the functionality of the product or of the elements inside the component. In order to achieve the requested precision and quality standards, mold has therefore been designed with an unconventional approach. The configuration with which it has been designed is indeed the opposite of the traditional one. The piece is picked up by its external part and not by the internal part as it usually happens: in this way we avoid both burrs and extractors in the internal part of the product.
After the optimization of mold design we also introduced during production cycle an automatic system for threading. This system, integrated into casting area, allows both the cutting of sprue runners and the simultaneous threading of two M8 holes. There are two important benefits that result from the implementation of this system: first of all we avoid manual operations (so the operator is free to deal with activities with greater added value) and, moreover, we obtain productive efficiency and continuity, with a resulting cost and time saving. Die casting technology, in particular die casting for electronic steering lock, thanks to our innovative approach and to the technical expertise of our engineers, constitutes a great choice for the production of automotive components because it ensures production accuracy also for the most complex products.
Die casting for automotive: sunroofs
In this video we present a component for automotive industry characterized by very close tolerances and complex geometries.
This part is a component for car sunroofs that has a complex shape and is characterized by very thin areas. Therefore it requires a high level of detail and accuracy. To meet the requests of the costumer we have adopted specific technical solutions that have assured the functionality of the piece and, at the same time, have allowed us to obtain a product free of every minimal deformation.
These solutions have been implemented in mold design phase and during the simulation of the filling flow, while the implementation of the injection channel, tilted sliders and ejectors has been managed in every detail to achieve complex shapes. For the simulation we have used Magmasoft software, which has allowed us to optimize filling flows in the entire die cast and in particular in the thinnest areas. The outcome has been a uniform and homogeneous filling. In addition, to increase even more the accuracy of the result, we have employed the vacuum technology, a tool designed and realized here in Bruschi to guarantee dimensional stability.
The technical solutions devised by the engineers have allowed us to achieve a product that has excellent technical features, compliant with our production process and that meets the complete satisfaction of the costumer. For the automotive industry, in this case for the production of sunroofs components, die casting technology allows the achievement of products with close tolerances and complex shapes that fully meet strict standards of the sector.
Die casting for building industry: windows and doors
In this video we show the production of the cover of the opening and closing system for windows and doors.
The component is part of the opening system for windows and doors: so it is characterized by functional and aesthetic properties. On the one hand, the functional properties are determined by the fact that the component contains in its inside other elements of the opening system. The aesthetic properties, on the other hand, derive from its nature of external element that comes in contact with the end costumer. For this reason the piece must have an optimal surface quality.
Therefore, to design and produce this component, we have considered various different aspects and we have found solutions able to ensure aesthetics and functionality. As regards aesthetics we focused on avoiding the formation of air entrapments in the die cast to obtain a surface suitable for powder painting. To obtain this kind of surface quality we used simulation software and the vacuum valve: these solutions permitted us to reduce painting scrap from 30% to about 0%. Concerning the functionality, instead, we have developed in collaboration with the costumer a re-design activity of the internal part of the component, aimed at reaching thin wall thickness that would maintain the properties of the product unchanged. Thin wall thickness, in windows and doors opening system, are important because the component has in its inside the fixing and the sliding system of opening mechanism and the reduction of thickness improves its functionality. The benefits provided by the reduction of thickness are considerable and concern less quantity of raw material and cycle time reduction. However, the production of the component does not confine itself to casting process. Indeed we have designed and realized an automation for the threading of 6 M5 holes. The threading phase is immediately after casting stage: the product passes through a vibrating device and after on a rotating table with three threading stations. The implementation of this automatic threading system has resulted in a considerable reduction of timing of the secondary processes.
Years of experience in die casting for windows and doors, technical skills and know how, have made it possible to produce a component characterized by specific aesthetic and functional properties and able to satisfy the costumer’s requests.
Die casting for household appliances: hinge for washing machines
In this video we show the production of the hinge for washing machine and the technical solutions adopted to guarantee the functionality of the product.
The hinge for washing machines is a functional component of the opening system of the porthole of the household appliance. This element has to meet specific technical characteristics and functionality requirements requested by the costumer. It is a product characterized by a very complex shape that poses interesting challenges during design stage and production process.
The observance of the costumer’s technical and functional requests, the need to adapt the production of the piece to our production process and the complex shape of the component, have required a careful activity of co-design with the costumer. Co-design allowed us to successfully exchange information and experiences, to realize a prototype mold with one cavity, to carry out functional tests and to verify process reliability. All these activities have led to the optimization of the shape of the hinge for washing machine.
The optimization of the hinge for washing machine has then also concerned the production process. In this phase we have introduced a dedicated automation that is directly connected to the casting machine. The automation allowed us to reduce the presence of faults on the die cast caused by manual operations and, consequently, it has reduced the workload of the operators. Indeed the operators could deal with more value added activities such as, for example, quality control and the improvement of production processes, with important benefits in terms of time and cost saving.
At the end, the last implementation has been dedicated to assembly stage. We have designed and realized in-house and ad hoc for the costumer a machine for semi-automatic assembly of plastic bushings on zamak die casts. The hinges are placed on the machine in different positions that are functional to the version of the product that is assembled in a specific moment. The machine, which has loading, assembly, control and unloading stations, makes the process vertical and is able to offer an end product.
All these solutions (co-design, automation directly connected to the machine and the semi-automatic assembly) have allowed us to minimize the error margin, to reach the quality requested by the customer and to increase the security of the production process of the hinge for washing machine.
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