Productivity enhancement represents, indeed, an advantage both for the supplier and the client: on the one hand the supplier benefits from costs savings, while on the other hand the client can rely on a partner that offers quality performances in short times. Bruschi has always considered this subject a core aspect, as a matter of fact through the years Bruschi has taken several measures in order to achieve an ever-increasing process improvement.

How to reach process improvement

Process improvement can be developed through a well-defined action plan, which takes into consideration the complexity of elements that characterizes the production department. Production is indeed composed not only of machinery, but also of product design, technologies, operators and planning activities, to mention some of the most important components of this structured system. To improve the production process it is therefore crucial to have a comprehensive view of all these elements, in order to implement a strategy that is functional on multiple aspects.

As a consequence, the first step to take is the setting of the tools and of the adjustment actions that can impact on the improvement of the different stages of the production. In Bruschi the process improvement plan is composed of four central elements:

1. Automation

2. Simulation

3. Scrap reduction

4. Cycle time

1. Automation

The introduction in a production system of automated machinery equipped with state-of-the-art technologies generates relevant benefits in terms of reduced lead time, costs reduction and achievement of quality standards requested by clients. The replacement of workforce with automated systems allows, indeed, to obtain a faster process, consequently enhancing the whole lead time. In addition to that, automation leads to a reduced likelihood of error compared to manual operations. This translates into a relevant production costs reduction, which is further increased thanks to energy and material saving that automation generates. The introduction of automated machinery in the production department produces another significant advantage that allows quality control improvement, too. As a matter of fact, operators that previously dealt with manual operations on the component thanks to automation can take responsibility for other activities with a higher added-value, such as quality control.

A process improvement project of a specific component, for a client of the sector of small appliances, has obtained excellent results in terms of increased productivity and decrease of manual activities of operators. Process improvement project has been developed in order to solve a situation of misalignment between production capacity and client’s demand. Through the introduction of automated systems this gap has been narrowed, thus achieving an optimized cycle time. After several studies and researches it has been possible to apply some changes to the process, which have brought to significant benefits: an increase of 33% of production capacity and a decrease of -95% of manual activities made by operators.

For more detailed information on automation consult the post below:

• How automation helps improving the production process
• The Importance Of Automation Optimize The Production Time

2. Simulation

Simulation of the die casting process represents another essential element that impacts on process improvement: with simulation software engineers can indeed foresee material reactions inside the mold. This process is feasible thanks to a thermos-fluid dynamic analysis of the mold, known as CFD simulation (Computational Fluid Dynamics), which allows the engineer to detect potential defects, such as cold laps and hot spots, on the die cast. The simulation stage proves especially helpful to obtain an optimized mold design before starting with the production process. During this stage it is indeed possible to select the best mold design parameters to apply, so that potential defects on the piece are previously detected and, consequently, production costs and further mechanical operations are reduced.

If you are interested in simulation, here are additional posts on this topic:

• The Benefits Of Simulation In Die Casting Design
• Die Casting Simulation For Shrinkage Porosity Prediction
• How To Use Die Casting Simulation For Cost Reduction
• Hpdc Simulation For Die Casting Process Optimization
• Die Casting Simulation A Casting Process Optimization
• Hpdc Simulation Benefits For Die Casting
• Simulation For Hpdc Surface Aesthetical Quality In Automotive Case Study
• Simulation For Hpdc Shrinkage Porosity Case Study
• Simulation For Hpdc Die Maintenance And Optimization Of Set Up

3. Scrap reduction

Scrap reduction can be achieved through an accurate planning of the whole production process of a component. First of all it is necessary to carry out a product and process analysis that focuses on the causes of scrap. To identify these causes engineers must use simulation software to foresee every stage of the production, from design to finishing operations. Once again simulation proves to be an indispensable tool for zinc die casting process improvement, because it allows engineers to avoid defects and to check technical properties before starting with the component production, thus producing a consistent costs and lead time reduction. Once scrap causes have been figured out it is possible to proceed to the outlining of potential solutions to apply, identifying the most relevant steps in the production process and constantly checking them.

To know more about scrap reduction, here are extra posts on the topic:

• How To Reduce Scrap In Die Casting Process
• Simulation For HPDC Scrap Reduction Case Study

4. Cycle time

The expression cycle time defines the period of time required to produce a product. Cycle time represents a central variable in the production of a component because a reduced cycle time results in a reduced lead time, which is the period of time needed to accomplish a customer’s request in terms of supply. An optimized lead time generates an increase in the client’s satisfaction, because it allows the supplier to meet deadlines and standards demanded by the client. As a consequence, in order to guarantee a rapid and efficient service, cycle and lead time have to be enhanced to the maximum extent possible. Cycle time can be shortened paying attention to different aspects of the production process, especially to simulation stage and to technological systems of the production department. First of all, as already mentioned, it is important to simulate production and defining the best process parameters to apply for the production process. In this way potential defects will be avoided from the very beginning and, consequently, it will be possible to eliminate further mechanical operations. Another core element for cycle time shortening is the technological system of the foundry, whose technological innovation level can generate relevant time reduction during the production process. As a matter of fact, automated machines lead to optimized cycle times and to more accurate operations, discriminating factors for the achieving of performances requested by customers. Furthermore, periodical checks on machinery help understanding how cycle time can be further improved.

Check the posts below to learn more about cycle time:

• Process Optimization For Die Casting Cycle Time Reduction
• How Die Casting Cycle Time Optimization Can Help To Reduce Costs

Why process improvement is crucial for a business

Process improvement is a crucial element in the management of a business because it leads to production costs reduction and faster productive processes. With the aim of reaching these benefits it is therefore necessary to introduce automated technology and simulation software in the production process, and to optimize scrap reduction and cycle time. With the outlining of a precise process improvement plan lead time can be shortened and, as a result, client’s satisfaction will be increased.

To get updates on trends and innovations in the Zinc Die Casting industry, you are welcome to subscribe to our blog.

{{cta(‘90548e70-5fbe-47d0-802c-a042cefc67b6’)}}

The post Production process improvement in the die casting industry appeared first on Bruschi.

You can find a full list of discussed topics in our first post on the subject, by clicking here.

CASE STUDY CONSTRUCTION: Mechanical characteristics

The product we are going to study in today’s post is a door hinge. This mechanical component was designed to be subjected to medium-low stress intensity so, in contrast to other products in building sector, for this project esthetical characteristics were not relevant, while mechanical characteristics and resistance to wear were fundamental.

OBJECTIVE AND PHASES OF THE SIMULATION

The simulation objective was to minimize the defects that may influence mechanical characteristics of the door hinge: porosity and holes. The requirements for the component were:

• to be free of internal cavities and bubbles, caused by air entrapment, in the holes;
• to be filled correctly;
• no missing details;
• low shrinkage porosity both internally and in proximity of the feeders.

Thanks to previous experience in the production of similar pieces, our technicians knew that porosity is an extremely critical aspect for door hinges: the presence of holes and cavities, caused by the shrinkage of the part in proximity of the feeder, could reduce wear resistance and even cause the component to break when subjected to stress. In addition, incorrect cooling of the parts causes hot spots on the surface of the die, leading to the formation of cavities on the component surface.

The simulation analysis focuses mainly on the solidifying phase, with the objective of finding a configuration that allows homogeneous cooling of the part, thus avoiding the creation of hotter areas and prevent porosity.

RESULTS

The study of the filling phase focused on the analysis of the distribution of entrapped air. As you can see from the following picture, the quantity of air is minimal and evenly distributed in small amounts across the part.

Porosity is analyzed observing the behavior of the part during the solidifying phase: the most critical point is the feeder duct, where the alloy solidifies and contracts during cooling phase.

Contrary to the configuration used in similar parts that were previously made, where the feeder duct is perpendicular to the axis of the holes, in this simulation the duct is orientated parallel to the axis and its geometrical configuration is optimized to avoid the creation of hot spots on the part’s surface.

As can be observed in the image, in the new configuration the surface next to the feeders solidifies much more rapidly, subsequently diminishing the risk of shrinkage porosity thanks to the alloy flowing back into the feeder ducts or into the part itself.

The junction area solidifies quickly (colored in light blue), together with the rest of the product surface, lowering the surface porosity risk. The most critical area is the one right below the junction – as seen in the red circle – where the cooling is much slower because of the proximity to the feeder.

But as can be seen from the picture tagged “50% liquid”, the criticality should now be solved: the circled area is solid (colored in blue) while the core of the part is still liquid (colored in yellow).

The image above displays mold simulation: the part volume near the casting ingate leads to a really delayed solidification and to shrinking porosity as a direct consequence. In comparison, the junction re-positioning has reduced the issue of porosity thanks to a quicker cooling of molten metal.

The results of the simulation have been confirmed during the utilization of the die: the problem of shrinkage porosity, typical of this type of product, has been fully eliminated.

To sum up, the experience gained dealing with similar cases allowed Bruschi to identify the criticalities already in die designing phase and to study a solution through the use of simulation. The objective was to improve the resistance of the component by reducing shrinkage porosity: this makes the component more resistant to wear and prevents it from breaking under stress. The simulation study of solidification phase proved that placing the feeder duct parallel to holes’ axis increases cooling speed, thus reducing the risk of porosity.

Once again, this successful case study shows the importance of simulation in die casting: the application of new technologies can make a competitive difference on the market even in a millenarian industry such as metal working.

To learn more about the use of simulation software for zinc die casting, subscribe to our blog.

{{cta(‘90548e70-5fbe-47d0-802c-a042cefc67b6’)}}

The post Simulation for HPDC: shrinkage porosity case study appeared first on Bruschi.

Considering the metrology room as a part of production process is an advantage: it becomes an integral part of the process, such as the design of the die, machine setting or finishing, not just a post-production control.

In terms of production the metrology room inside of die casting plant allows to manage important activities, such as:

– Constant monitoring of each production cycle
– Fast check of new projects and sampling
– Getting an overview about projects that have undergone changes over time
– Control of parts incoming from external suppliers
– Reverse engineering, both for the product and the die

To achieve these goals, a complete range of tools and innovative machines is needed, complementing the precision of a traditional CMM system with a 3D scanning one, combined with the most advanced software for inspection and statistics, allows to accomplish a complete dimensional control.

Following, you can find an analyses regarding applications of a metrology room inside die casting process.

Constant monitoring of each production cycle
Pieces are dimensionally tested when they are still in the production cycle to ensure the correct quality. Products are taken directly from the die casting machine for dimensional and statistical controls: to cyclically evaluate the dimensional quality and, in general, to continue monitoring the reliability of the process.

Fast check of new projects and sampling
A constant dimensional control activity, especially in the project start-up phase or sampling phase, it is strictly necessary to reduce time and costs. Having a metrology room inside the plant allows real-time control of the pieces produced to immediately confirm the precision of the process or, in the opposite case, to have a real-time response in order to make changes or updates in production cycle.

Getting an overview about projects that have undergone changes over time
In case of dies or products previously designed and developed by a different supplier, it could be necessary to analyse and check them to ensure the dimensional quality required by the customer. In fact, without similar controls, the new supplier could face the same issues. This kind of analysis is essential to avoid this situation. Instead, by getting a complete analysis of the project, the new die caster will be able to act directly for updates, ranging from simulation software to machine settings.

Control of parts incoming from external suppliers
Having a metrology room inside of die casting plant could be also really useful in case of complex products, that need to be assembled with other components from a different supplier. In fact, in addition to the control of produced pieces, it is important check all the other parts of the product. This method assures to minimize risks for the customer.

Reverse engineering 
Dimensional measurements are very important in case of reverse engineering actions, both on parts and dies. It can be a helpful activity in order to analyse the market, or pieces already in production, or rebuild a component starting from the die. This methodology can be applied on different purposes, to speed up some projects.

{{cta(‘90548e70-5fbe-47d0-802c-a042cefc67b6’)}}

If you want updates on trends and innovations in die casting industry subscribe to our blog.

The post Dimensional measurement: production control and reverse engineering appeared first on Bruschi.

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.

The fundamental cause of shrinkage porosity has to do with the solidification phase: let’s dive into the meaning of that particular defect, possible causes and solutions.

What is shrinkage porosity

The term porosity is generally used to describe cavities produced within a solidified casting, due to specific volume contraction on solidification. Usually the ragged edged cavities are associated with the last areas to solidify in contrast to the smooth rounded voids resulting from gas porosity.

Identifying cavities size, shape, surface constituents, location and frequency is crucial to define the exact defect occurring and to determine its cause. On the one hand, some defects can be fixed during the manufacturing process, on the other hand, by changing the mould design you can prevent them avoiding extra works and costs.

For a customer knowing the factors that are going to contribute to the various defects means to be able to co-design with the casting supplier to avoid production problems.

Causes of the defect

In HPDC processes, when the liquid melt is injected into the die cavity, it flows through ingates at high speeds. When the mould cavity is completely filled, melted metal is maintained in pressure by stroke: in this condition the solidification phase begins. Cast material takes up less space when solid than when liquid and this space will appear where there is a hot spot in the casting. The shrinkage is as high as wall thickness is heavy. The causes of this defect are different wall thickness, cross section too thick, metal pressure too low, gate too thin for maintenance pressure.

To avoid frequent casting rejection the solidification process must be examined very carefully: gates and runner geometry, cooling channels, thermal cycle and pressure in the cavity are the areas object of the simulation analysis.

If the shrinkage porosity is small in diameter and limited to the very centre of thick sections it won’t cause massive problems. However, if it is larger in size, or joined together, it can severely weaken a casting. In the worst case porosity appear to the surface and impair the aesthetical quality.

How to avoid defects with simulation

The general technique for eliminating shrinkage porosity is to ensure that liquid metal under pressure continues to flow into the voids as they form. Engineers use computer simulation to have an analysis instrument for casting solidification study. This can be achieved by careful attention to the gating system, the cooling system, the die layout and the heat flow paths in the die.

In high pressure die casting process, castings and moulds geometry design, as well as casting parameters, gating and cooling systems, die layout and the heat flow paths can be optimized by using simulation programs. Data resulting from them are very valuable information for investigate the problem and make a diagnosis as well as in die design and process parameter optimization as they simulate casting solidification and predict hot spots.

HPDC simulation benefits are shared by customers and die casters, as the number of rejected products can be significantly reduced, leading to shortened delivery times, improved quality and indirect cost-reduction (less material waste and no need for empirical tests or trials).

In the computer simulation it is possible to identify shape and location of porosities and to predict air entrapment by tracking its flow.

An accurate solidification analysis can predict the occurrence, location and size of internal defects.

Using die casting simulation programs for shrinkage porosity prediction can lead to significant costs reduction thanks to major improvements in material and energy consumption, labour resources, and scraps reduction.

If you are using simulations to design or improve your die casting moulds and processes, please share your experience with us writing a comment here below.

To get updates on trends and innovations in the Zinc Die Casting industry, you are welcome to subscribe to our blog.

{{cta(‘90548e70-5fbe-47d0-802c-a042cefc67b6’)}}

The post Die casting simulation for shrinkage porosity prediction appeared first on Bruschi.

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.

Focus your attention on reduce scraps

Imagine to develop a new product, or improving an existing one. In this phase maybe you are not directly focusing your attention on reduce scrap: but this is the ideal step to cut cost in the future.

Focus attention on reduce scraps means simulate the whole procedure, from tools to machines, from mould to the finishing phases: such as mechanical machining, treatments or painting. Anticipating issue allows you to save time and resources, resulting in production process improvement.

You should figure out how the new product will be produced: starting from idea then to mass production.

This means have an overview all over the entire concept, engineering and mass production phases. In each of these steps you can cut cost reducing scrap.

Concept

In the first stage, in order to reduce scrap, is necessary working to understand the reason why of the product and its needs, in terms of structural and aesthetics properties. It is really important to identify the real function of the product, as components or part of design product, to figure issue after production.

After this step the prospect issues should be on the fluid dynamics and the mechanical of mould.

Engineering

In the engineering stage the focus should be on quote and the critical parts of the product. These are the most important details to check in order to avoid an important percentage of scrap.

To avoid issue related to them it is important plan two different activities: using simulation software and checking the production status.

About simulation there are some properties to check as uniform flow, filling temperature, reduce filling time (mould erosion must be avoid), distribution and pressure of the entrapped air, soundness and porosity.

In particular, in case of item with mechanical and structural requirements the most important properties are soundness and porosity whereas, if aesthetical quality is needed, it’s necessary to guarantee high temperature and uniform flow during the filling phase.

About production controls it is necessary to plan check points, from the design phase to mass production, paying attention on plan checks on the supplier’s work. This is also a fundamental step in order to guarantee the quality at your customer.

These checks should be in the entire process, but above all in the initial step, so to identify the problem without wasting time.

However these checks have a cost, in terms of resources and time: it is necessary a precise plan: to avoid to spend an extra budget instead of save thanks to them.

Mass production

At the stage of mass production it is important to implement all the results of the previously completed work and apply checks in the different stages of production, from the first concept to the suppliers.

CONCLUSION:

Complete the work by complete a file with all the statistics, with costs and save, could be useful to have the first case history to applied for others products.

To get updates on trends and innovations in the Zinc Die Casting industry, you are welcome to subscribe to our blog.

{{cta(‘90548e70-5fbe-47d0-802c-a042cefc67b6’)}}

The post How to reduce scrap in die casting process appeared first on Bruschi.