Advantages of Die Casting Process Advancement

Update:Oct 28 2016

In some companies, cost, quality, and speed are three c […]

In some companies, cost, quality, and speed are three components in a dynamic equation that forces their customers to make choices they may not want to make.

For example, a company might tell their customer that if the cost is to remain a constant, but the speed needs to increase, then the quality of the die casting has to be decreased to compensate. Similarly, if the customer says that the cost has be decreased, the company might tell them that either quality or speed (or both) must be decreased in order to keep the price down.

Many customers, however, are no longer willing to make those sacrifices in order to keep prices down. They want these all.

The question is: Is that possible? Can a company produce die castings faster, of higher quality, and reduce costs at the same time?

The answer is no if we continue to do business as we have been doing it all along. Something will have to change - but what?

Until recently, much of the process of high pressure die casting has been done by the use of 'trial and error' method, but one that also can drives costs up, limit quality and delay production. Unfortunately, some projects are so complicated that using 'trial and error' means that a high quality casting is never produced, and the end result is a die casting that doesn't meet the customer's needs, while costing a lot of money for the die caster.

Luckily, with the development of technology, the process simulation software tailored to the specifics of the high-pressure die casting process helps to avoid the uncertainties of 'trial and error' and provides a clear picture for the die caster about what to expect throughout the die design and casting process. With this software, it is possible for the engineers to simulate, understand, change, and optimize the casting conditions before the process is ever introduced to the shop floor.

Available on the market for over 20 years, process simulation software is used by the modern die caster on a daily basis. The first simulations are done as a part of the quoting process in order to get a better understanding about the project. After winning the bid, the die design is simulated. The feeding and overflow system as well as the cooling and heating channel locations are changed until a good die casting condition is shown. Potential weaknesses can be determined, corrections made, and simulations rerun until the customer's goal is met. Using simulation, today's engineering process is significantly faster, the casting quality is higher, the costs is lower, so the customer can get the quality, price and speed they want simultaneously.