Cost reduction strategies in zinc die casting

Cost reduction in zinc die casting can be implemented in different ways. In fact, zinc is a versatile metal that, if manufactured with the right technologies, allows saving not only in absolute terms, because it allows the die caster to save the time, energy and raw material that are required in the process, but also compared to other metals.

In the production of die-casts it is possible to implement cost reduction by:

•  Choosing zinc instead of other metals or other metal alloys
•  Optimizing the productive process
• Designing processes and components together with the customer through co-design methods

  When it comes to save during die casting process it is also important to choose the right die caster, if you want to learn more on the matter read How companies can save while selecting the die caster.

Advantages of zinc: chemical and physical qualities and characteristics, melting temperature, circular economy

Zinc alloys usually employed in the die casting process have some properties that make them competitive if compared to other metals. These are chemical-physical properties that allow the reduction of costs related to productive processes and to the subsequent stages, such as, for example, those of disposal and recycling. Let’s analyze these characteristics in detail.

Chemical-physical qualities and properties

In the die casting process different zinc alloys are employed. The most common of those alloys are Alloy 2, 3 and 5, and they are chosen for the production of different components depending on their chemical-physical properties. In fact, according to the percentage and the relative values of the metals that are contained in them, the alloys have different characteristics that make them more or less appropriate to realize different typologies of products. For example, if the component is a safety product the alloy that guarantees the greatest resistance to wear, corrosion and pressure, yield strength and dimensional accuracy is to be chosen. In case of a technical component, for which it is often important to achieve details and thin ribs, the Zamak to be preferred will be the most fluid because it will be capable of spilling over the mold in the most uniform way. In this way it will be possible to obtain thin walls thickness that is essential to guarantee the functionality of products. Finally, for aesthetical products Zamak alloys able to ensure the best surface quality and the best performance if subject to subsequent processing and finishing, are to be preferred. Therefore it is very important to know the chemical-physical characteristics of the different zinc alloys in order to choose the most suitable for the production of a specific component. Only in this way, in fact, it is possible to make a winning choice and obtain, with reduced scrap rates, quality die casts that need a reduced number of finishing and further processing.

If you want to discover more about different zinc alloys and how to take advantage of their specific characteristics read the articles The best zinc alloys for hot chamber die casting and Zamak molding in hot chamber die casting: chemical composition.
To deepen your knowledge about the advantages of zinc in comparison to other metals read The importance of zinc die casting in automotive industry and Coating, plating and other kind of surface treatments.

Melting temperature

One chemical-physical property that has a great impact in terms of cost reduction is the melting temperature of Zamak. The melting point of Zamak, in fact, is low and this allows hot chamber die casting. Differently from aluminum, which has a higher melting point and that is cold chamber die cast, Zamak allows energy saving provided by the different technological process used to melt the material. There are further advantages related to time that are connected to hot chamber die casting: hot chamber die casting is a faster process than cold chamber die casting and, as a consequence, it has an increased productivity. Another saving factor related to melting temperature is that the mold, subjected to lower temperatures, is affected by less wear and, for this reason, has a longer lifetime, with beneficial effects especially in large scale production.

Circular economy

In this brief review of the qualities of zinc in comparison to other metals one last property has to be mentioned: recyclability. Zinc, in fact, fits in circular economy processes and therefore meets the recent trends toward environmental sustainability. Zinc recyclability is not only an advantage for the final consumer, who can recycle products and appliances, but it is also an important factor of cost reduction for the die caster. In fact, if the agreements with customer allows it, zinc can be re-melted and, in controlled percentages, it can be reintroduced in the productive process with evident consequences in terms of reduction of scrap rate and of optimization of the productive processes.

If you wish to learn more about the possibility of recycling Zamak click here.
If you look for insights on zinc circular economy we suggest you to read Zinc life cycle: how it contributes to circular economy.

Productive process optimization

In regards to cost reduction in die casting not only the properties of zinc are important but also the productive process with which the metal is manufactured. Die casting techniques and machineries have to be up to date with technological development in order to be efficient, for this reason constant research and innovation are necessary. It is also important to have effective supply chain and logistic managment, if you want to learn more click here.

For a general overview about these topics we suggest you to read the article Production process improvement in the die casting industry. If you wanto to deepen your knowledge on the  analysis necessary to optimize the productive process read the article How die casting companies can help you save time and budget.

Automation and cycle time

An important step to achieve cost reduction is, for example, the introduction of automation in the productive process. In fact, automation makes the system more efficient by diminishing the percentage of scrap and allowing the operators to deal with activities with a greater added value.

Moreover, the acquisition of automation is closely related to the capability of updating and implementing the productive machineries. Thanks to the purchase of new machineries activities that used to be manual become automatic with a resulting diminishing in lead time, cycle time and scrap rate and a noticeable increase in productivity. Cycle time, in particular, is very important in relation to cost reduction strategies: in fact diminishing cycle time means increasing OEE, the productive performance index of a plant, and, consequently, the production. In the specific field of hot chamber die casting the reduction of cycle time represents a further saving opportunity because, in a reduced cycle time, the thermal power that the melted material provides to the mold is increased with a resulting decrease of cold fronts and related defects.

If you want to learn more about automation and its importance for the production process read How automation helps improving the production process; if you want to discover more about cycle time and its optimization we suggest you to read How die casting cycle time optimization can help to reduce costs.

Simulation

Another strategy to optimize the productive process is to use simulation software that allow designers to forecast what is going to happen during the die casting process. Simulation is a useful instrument to prevent problems, errors and defects during the production of the die casts and it is, moreover, a fundamental aid during design, prototyping and testing phases.

You can find a study about the advantages of simulation in zinc die casting clicking here.

Quality certifications

A guarantee of optimization of the productive process and of the subsequent cost reduction is the achievement of quality certifications. Smeta 4 Pillars, for example, is a certification of qualitative standards, environmental management, company integrity, health and safety with a noticeable impact in terms of cost reduction. In fact, Smeta 4 Pillars through the sharing of standardized approaches improves and aligns the productive process safeguarding brand reputation and guaranteeing an ethical supply chain.

Co-design

Co-design consists in a series of activities aimed at increasing the value of the product and at improving it in terms of quality and efficiency. Often these activities do not result in an increase in production costs but, on the contrary, they result in a decrease in costs. Through co-design, if already implemented during designing phase, it is possible to agree with the customer on weight reduction, elimination of secondary operations, optimization of the mold and a number of other actions that directly lead to a noticeable cost reduction. Obtaining a drawing that is already optimized for mass production allows the customer to have a final product that is in line with expectations and with less risks and scraps. As a further assurance of cost reduction, already during co-design phase, it is possible to undertake a VA/VE value analysis and to optimize the process through the DFM. VA/VE value analysis is a method of problem solving that allows the effective identification of unnecessary costs making it possible to reduce them. DFM, Design for Manufacturability, is a feasibility study in which the design of the product is evaluated and in which adjustments, special treatments and structural modifications are proposed in order to make the optimization of the production possible.

For a deeper insight on co-design we suggest you to read the article Product design for die casting, if you want to deepen your knowledge on VA/VE read The zinc die caster impact on production costs reduction. 

The methods to implement cost reduction in zinc die casting and to optimize processes and products do not end here. However, by reading this article you should have had evidence of some important benefits of cost reduction.

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Supplier’s impact on VA/VE

An increasingly important part of procurement strategy is to involve suppliers and strengthen collaboration in product development, cost reduction and enhancement activities.

Joint Value Analysis/Value Engineering is one of the best ways to pursue long-term goals and to establish good business relationships with suppliers: trust and open-share of information and ideas are the basis of commercial collaborations.

Informing and involving suppliers in VA/VE activities can help to clarify the process definition and to encourage alternative proposals, resulting in more competitive price and/or better product.

The benefits of cost saving, process improvement, and transparent communication are shared between suppliers and customers. The former is able to determine a calculated cost reduction, to show potential quality improvement or scrap reduction with supporting data; the latter can benefit from open communication, cost reduction and/or better quality.

A supplier involved in VA/VE analysis can make proposals for:

Component design changes

These modifications are usually proposed by a dedicated engineering department and studied using simulation and analysis tools to support customers since the beginning of a project. These changes can help to reduce scrap production and component’s weight, to improve structural and mechanical qualities of the piece and to prevent future issues. All these activities lead to improved functionality of the components, therefore increasing their value.

These changes may regard:

• Materials or specifications
• Dimension or tolerances
• Components substitutions

Manufacturing or assembly process changes

With simulation software, it is possible to try out a number of process variations to obtain the best optimization possible without wasting any material. These tools make it easier to spot critical points and to apply correction where needed, especially in those situations in which the root cause may not be clear just by analyzing the casted component.

Modifying the process and the technologies involved before creating a prototype or casting a trial batch grants a great saving in terms of material used and less machine time wasted. In other words, during a VA/VE analysis the simulation of manufacturing process can increase the value of the product by reducing costs.

Some of these changes may regard:

• Tests reduction
• New process technology
• Part reliability

Logistics

A better communication between parts is crucial to achieve a functional supplier network. Sometimes the supplier can take care of shipments costs, adjust schedules to meet urgent needs, or even arrange shipments to make the most FLT (Full Load Transport) possible, thus cutting costs.

Some area of Logistics in which suppliers can help are:

• Reduced freight costs
• Packaging improvements
• Inventory management

Once the customer’s procurement receives proposals, a team composed of experts from different departments will review them to determine feasibility and eventually merge the new obtained result in their procurement strategy.

How a Die Caster can support VA/VE activities

Product engineers are always trying to reduce production and material costs, maintaining at the same time the quality of products. Value Analysis / Value Engineering is fundamental to reach that goal.

We can classify manufacturing costs into:

• Raw materials
• Labor
• Process

Let’s see each point in details.

Raw materials

As every procurement strategy specialist knows, raw materials prices depend on a wide range of factors, from widespread availability to fluctuation of the market.

Sometimes a change in material can be necessary to keep the production costs under control, or to cut unnecessary costs and increase the revenue for a product. For example, choosing to use zinc instead of aluminum, stainless steel or any other material could help to cut costs.

But even when using the same material, there may be differences in price and quality: for example, zinc alloys come in wide varieties and in different price sets. Choosing the right kind of alloy is important not only for the final product, but it could also help saving. To be sure to choose the best material both in terms of technical quality and cost-wise,  it is advisable to ask your supplier for advices by involving its team in your VA/VE analysis.

Labor

The manufacturing process necessarily includes labor costs: some of these may be avoided by speeding up the operations, for example through the use of automations, or by carefully designing components to reduce after-production operations and make the assembly easier.

Process

Process requirements can vary greatly depending on the industry. When considering die casting industry, the typical cycle time is composed of the following phases:

• Injection time;
• Die casting technical time;
• Mold shifting/lubrication time;
• Control time;

There are different ways of optimizing these processes, but in many cases automations and IT can help. Some programs can simulate the entire production cycle: based on data acquired from the analysis, it is possible to anticipate any issues and minimize risks, finding the most suitable solution for each project.

To conclude, we have seen how involving die casting suppliers in a jointed VA/VE analysis can help improving different phases of the production: from product design to process optimization, almost every area can benefit from an expert suggestion. Therefore, contacting suppliers while developing a new procurement strategy could increase the value of a product, either by improving component’s functionality or by reducing production costs.

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VA/VE Analysis History

In 1961, in his book “Techniques of Value Analysis and Engineering”, American engineer Lawrence D. Miles stated:

 “Value analysis is a problem-solving system implemented by the use of a specific set of techniques, a body of knowledge, and a group of learned skills. It is an organized creative approach whose purpose is the efficient identification of unnecessary costs, i.e. cost that provides neither quality nor use nor tool life nor appearance nor customer features.”

The term Value Analysis / Value Engineering originated in the early days of technique development and its first approach was to increase value, rather than to reduce costs. Therefore there was a need to analyze value.

Lawrence D. Miles continues:

“Value analysis approaches may assist all branches of an enterprise-engineering – manufacturing, procurement, marketing, and management – by securing better answers to their specific problems in supplying what the customer wants at lower production costs. Quite commonly, 15 to 25 per cent and often more of manufacturing costs can be made unnecessary without any reduction in customer values by the use of this problem-solving system in significant decisional areas.”

VA/VE is an extremely powerful approach with over a century of worldwide application and it can be applied to any cost generating areas with equal success.

Il VA/VE è un approccio estremamente efficace con oltre un secolo di applicazioni in tutto il mondo e può essere applicato ad ogni area che genera costi con lo stesso successo.

Value Analysis / Value Engineering Definitions

Value Analysis – VA

What is value?

Different customers will answer to that question in different ways. The value of a product can be the performance of its functions or its aesthetic beauty, when applicable and needed. As a general statement high level performances, capabilities, emotional appeal, style, all compared to cost is commonly what we consider as value.

Therefore Value = Function / Cost

Value Analysis is a standardized, multi-skilled team approach which aims at identifying the lowest cost way and ensuring the highest worth to accomplish the functions of a product, process or service. Value analysis means to assess product functions and value-to-cost ratios, and to find opportunities for costs reduction.

Value Engineering – VE

As we said above, Value Analysis is the application of several techniques to identify the functions of a product (or service) and provide them at the lowest cost.

Value Engineering refers instead to the design stage. This approach is generally used for new products, therefore the same principles and techniques to pre-manufacturing stages such as concept development, design and prototyping are applied.

To sum up, VA / VE is an orderly and systemic method to increase the value of an item, which can be a product, system, process, procedure, plan, machine, equipment , tool, service or working method. Function analysis is part of VA as its purpose is to identify product functions compared to cost and price; design and construction assessment is done through VE with the goal of  eliminating elements which are not contributing to function.

Product’s function should not be conceived solely as its application and practical uses: it can also include aesthetic factors, or the union of the two following dictates of functional beauty philosophy: this theory is based on the coexistence of aesthetics and performance. What matters the most in drafting a VA / VE is that the function is clearly defined, so that it can be analyzed in detail and sub-segmented to make the analysis easier.

If you are interested in functional beauty, Bruschi is going to give a lecture on the topic: click here to learn more.

In VA/VE the function of a product or service, defined by customers to meet their requirements, is identified, the monetary value for that function is established, the specified performance and requested reliability provided at the lowest Iife-cycle cost.

Following a VA/VE approach it is possible to increase customer satisfaction and add value to the investment.

Even the best and most innovative designs can age and become uncompetitive: in these cases VA/VE can support both customers and suppliers in finding and optimizing any value mismatches in products, components, processes, projects or low performing functions.

A correct segregation between necessary and unnecessary functions of products leads to a creative development of alternative ways of accomplishing them – as requested by customers – at lower cost.

VA/VE enables a company to highlight areas that need to be analyzed and improved, with a standardized method which generates ideas and alternatives, considerably increasing the value of goods and services.

A project completed with VA/VE technology is more successful and efficient than a project developed without that approach, because goals and requirements are pursued in a customer centric way. VA/VE is almost unlimited in identifying area of potential savings, as it can be used to reach quality, improve efficiency and reduce risks, in a cost saving way.

VA/VE Approach & Main Steps

According to the principles of “Techniques of Value Analysis Engineering” there are different phases of VA/VE:

• Exhaustive accumulation of information and identification and improvement of assumptions.

• Penetrating analysis. What senses of direction does this informative provide us with? What specific problems will, when solved, bring important cost benefits?

• Creative mental activity, in which all judgement is temporarily deferred to form the roots of a variety of different solutions to each of the specific problems developed in the preceding analysis.

• Judgment-type mental activity, in which what results from creative thought is searched for ideas roots to minimize disadvantages and maximize advantages sufficiently to meet the need for cost and/or operation improvement.

During the information phase, the project and its requirements are analyzed, and then the function analysis studies the possible room for improvement. In the creative stage ideas to increase performances are developed: from the resulting list of ideas only a short set is evaluated in order to find the ones with best potential to reach the goal. The following step is development of alternatives and their presentation to decision makers and, eventually, implementation.

VA/VE tools are extremely powerful and fundamental to reach objectives such as decreasing costs, improving quality and shortening time-to-market.

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It is important to remember that not every defect can be avoided during die casting phase, but it is necessary to focus on mold design. This happens because during production phase it is possible to act on a limited number of parameters and sometimes to solve a problem the designer can only modify mold design.

Die casting defects : explaining their characteristics

Casting defects are caused by an incorrect filling or solidification phase and they can be divided into two category:

Internal:

• Gas porosity
• Shrinkage porosity
• Inclusions

Superficial:

• Cold laps
• Laminations
• Blister
• Cracks
• Lakes

Internal defects

These kind of die casting defects are more difficult to find and are responsible for weakening component structural resistance.

Gas porosity

Due to fluid high speed during filling phase turbulences are generated, these turbulences can include air or other gases. During solidification phase, if gas concentration is not homogeneous inside casting, air bubbles generate cavities which weaken resistant sections of component.

These cavities are rounded and can be shiny or opaque, depending on gas type entrapped during filling phase: for example air, water or lubricant.

Shrinkage porosity

Shrinkage porosity defects are created during solidification and cooling phase of casting. They are created due to material shrinking and for this reason are widely spread in massive parts.

During solidification phase, the material tend to move near colder zones, for this reason, due to different temperature between casting surface and core, cavities are concentrated inside the part. The morphology of these cavities has an angular shape.

In some cases there is the risk of creating cavities on component surface if part and runner geometry is suitable for hot spot setting up.

Inclusions

In zinc alloys intermetallic compound can be created: in particular the most common is FeAl₃, which is a compound of iron and aluminum.

Is important to say that these compound are tougher and have a different colour than zamak alloy: for this reason can cause problems during following phases of mechanical and finishing process.

Moreover with components under mechanical fatigue stress concentration and cracks can be created.

Superficial defects

These kind of casting defects are visible and worsens component surface and its aesthetical quality.

Cold laps

Cold laps are the most common die casting defects: they are caused by irregular flows and low temperatures. Cold laps include a wide selection of defects such as flow marks or lack of material. Depending on defect rate components can have a poor surface quality or in the worst case it can be incomplete.

This phenomenon is generated from matching two or more flows of material which, due to low temperature, oxide formation and dirt inclusion, flows welding is incomplete or absent.

Laminations

Laminations can be classified as part of cold laps category. They are generated from overlapping of two layers which are always separated during filling phase.

These defects are difficult to detect after die casting, while they appear after finishing or pre-finishing operations like tumbling and sand blasting. During these phases, the impact between inserts and casting causes lifting of subtle zinc layers.

In the middle of these layers other fluids and dirt of die casting process like lubricant or oil can be hidden. These substances can come out during surface treatment like painting or galvanization and worsen the outcome.

Blisters

During mould filling phase, air inside the mould and machine is compressed, and one part is ejected from the casting using vacuum valve, chill vent or overflows. Air remained inside the component can be dissolved inside the melted metal with an homogeneous distribution. Due to many turbulences, air is concentrated creating high pressure cavities.

Very often, if the component does not have high temperature extra operations, this die casting defect is hidden and causes diminishing of component strength; otherwise in processes like powder painting where the temperature is higher, gases inside the casting expand and generate bubbles on the surface.

Cracks

Cracks are material breakage caused by stress inside and outside the material.

The first ones are created during solidification and cooling phase: due to cavity geometry material is not allowed to shrink in its natural directions, what results is residual stress that can generate cracks inside the mould or deformations after ejection.

The second ones are caused by external forces on components: these forces can be found during parts ejection from the mould or cutting phase.

Lakes

These kind of defects are seen in aesthetical components: are caused by different solidification time of the filled metal which in some part of the casting generates a different skin from the surface. This area is fine grained and appears different from the rest.

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The importance of choosing the right zinc die caster

The right partner is able to help its customers to reach planned goals and to develop a product or component but, on the other hand, having a bad zinc die caster could prevent the client to obtain results.

To obtain a significant cost reduction zinc die casters can offer to its customers a co-design service, to improve the design or functionality of the product, or a reduce costs service helping the client on its VAVE, that due to this collaboration turns to be tailor made.

In fact during the initial phase of die casting process the designer need to be focused on different aspects to obtain a functional product that at the same time reaches aesthetic requirements. The perfect balance between these two elements allows to obtain a product that can meet clients’ expectations with a cost saving approach. In this case supplier’s technicians can help the designer: this means stay on the client’s side in its VAVE.

What is VAVE?

VAVE is a systematic decision-making process. Its purpose is to solve problems, reduce costs and, at the same time, to improve the value of a product. Suppliers, with a customer centric approach, can help clients in their VAVE with an improvement of an already existing component or process, or designing a new one.

With the supplier’s expertise, specialized in a particular field, in fact can be even better.

Why VAVE is so helpful?

VAVE can help a company to generate new ideas and lead it to innovation, having a more competitive price, better products in a cost saving way.

The right zinc die caster is able to help companies’ VAVE in order to obtain a more functional product with a cost and time saving approach, identifying the lowest cost way possible mixed to the highest worth to accomplish products functions.

VAVE could be the best way to reach long term goals to better collaborate with zinc die casters. This relationship must be based on trust and share information and ideas. In fact zinc die caster involvement during VAVE can lead to an exchange of ideas and proposals for changes in terms of component design, manufacturing or assembly process and logistic.

How can saving be obtained in die casting?

A die casting company can obtain savings in different ways: first of all choosing the material, then finding the right assembly process and finally using simulation tools such as MAGMASOFT to prevent any problem during the process.

The supplier is able to obtain an important saving in terms of money and time for the client centralizing operations in its plant, in order to reduce lead time and unpredictable issues due to segmentation, before being assigned to different zinc die casters or other suppliers.

Surface treatments, mechanical operations and assembly in fact could be done in the same plant to guarantee to the client finished or semi-finished products using one supplier that simplifies the procedure.

In this case, also the product quality is increased due to these procedures, to the optimization of the entire cycle and to the prompt participation in case of non-compliance products.

Optimization of phases for cost reduction

Regarding cost reduction in die casting field is important to have a look on simulation phase. Simulation is a key element of die casting process, implemented at the beginning of the production of the component.

Simulation is one of the most important way through which is possible to obtain a significant cost reduction during every step of die casting process. In fact every step that can be improved allows a saving during productive life of a component: for these reasons it is important to analyze every part of the entire process to understand how to save in economic and time terms.

Cost reduction in production process

In terms of cost reduction reduce time and cost production are the most important parameters to optimize during die casting process:

• Reducing cycle time
• Reducing masses of feeding channel and overflows
• Obtain a thermal balance of the mould reducing wear to reach the requested aesthetic quality

Reducing cycle time

Cycle time can be reduced simplifying each segment of die casting process or minimizing its duration to act in order to obtain cost reduction: implementing necessary phases and cutting the non-necessary ones, not damaging product quality.

Reducing masses of feeding channel and overflows

To avoid any secondary deburring is necessary to eliminate runners and overflows to obtain finished or semi-finished components that during secondary operations will be treated to reach clients’ expectations with a cost saving approach.

Obtain a thermal balance of the mould reducing wear to reach the requested aesthetic quality

It is necessary to reach a correct thermal balance of the mould to avoid cold laps and other issues. Summarizing working deeply on mould design can prevent other defects and, consequently, is possible to reach a better outcome of the product.

There are other aspects to be analyzed but they are not related to die casting process directly. In this category is possible to highlight the management of the process, phases of sorting and controlling of products and finally the packaging, that is the first element that a client sees. Every aspect can be seen as a way where is possible to obtain saving if it is optimized in a correct way.

Conditions to be beared in mind during die casting process

In die casting companies there are different person involved during die casting process such as the producer of raw materials, the toolmaker, the die caster, the designer and other responsible for secondary operations.

In particular the designer has a central role during product design of a product. In fact its role is fundamental also before casting, when there are many other conditions to consider: for example is important to estimate the right number of cavities of the mould. If this number is underestimated the company cannot satisfy its clients’ orders, while if this number is overestimated the production can face a higher risk of producing scraps.

These conditions have an important role from an economic point of view and for the relation with the client.

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VAVE analysis is a systematic and organized method to drive down the product cost and improve profitability of products. The first step of cost reduction is to decrease material and production costs: it is important to choose the right material, the most useful assembling process and to use a prototype and a simulation tool to avoid any problem during the production cycle.

Involving zinc die caster in your VAVE

The supplier has the chance of using simulation, prototyping, testing and process optimization. The supplier can suggest which can be possible problems before the production and suggest ideas to avoid them.

Is difficult to find and choose the right zinc die caster, but having the right partner may be what makes the difference. In fact the right supplier helps to reach goals and can help to optimize an already developed process. It has knowledge of the entire process and knows how to optimize and improve it.

Below three areas to improve thanks to the right zinc die caster:

• Co-design
• Simulation
• Benefits of Zinc

Improving ideas with co-design activity

Co-design is the relation established between zinc die caster and client. It is really important that they collaborate and share information since the first phases of a project, both for new product or existing component.

This activity sustains the client in terms of morphological innovation, minimizing risk, mass production and saving.

In fact the right die caster is able to support its client in all phases of this process such as simulation, prototyping, testing, time to market, process optimization.

If the client does not share with the supplier the entire production process the product could be weakened in its performance and function.

For this reason the right choice of a zinc die caster allows the client to have an engineering department fully dedicated to analysis and simulation tasks, just to guarantee the best support during the product design phase from the beginning.

After this phase the perfect supplier should also have the possibility to do rapid prototyping inside its structure, directly using pilot tool, with no need of sub-contractors for the testing operations. Rapid prototyping enables a direct connection to the next production stage: the construction of the mould. This makes the whole process faster defining standards of quality that will remain constant at each stage of the production process.

Once these starting phases are concluded the experience and expertise of the right die caster will be on challenge during the mass production phase and during finishing or machining phases.

Benefits of simulation tools

Using simulation tools is possible to improve quality of a product and reduce scraps in cost and material saving terms.

Using MAGMASOFT simulation software brings many benefits such as improving aesthetic quality, reducing the number of rejected products, a faster production cycle, higher process efficiency and cost reduction due to elimination of secondary manufacturing.

The benefits of die casting simulation are really important because thanks to these analysis it is possible to modify the parameters of different variables such as injection curves and mould temperature.

Die casting simulation technologies allow to modify both the product design in the start-up phase, and the ongoing process performances. The simulation software can help the specialist analyzing real time data to identify critical points in a mould already in use and avoid non-compliant.

The casted product can be non-compliant for different defects which now can be identified before production thanks to simulation technologies. A proactive approach can anticipate problems such as flow marks and blisters, cold laps, porosity, shrinkage porosity, lakes and shot to shot inconsistency.

Avoid non-compliant, as a better product optimization in co-design phase in terms of product design, helps to avoid material waste.

The optimization of the correlation between scrap material and material that compose the item allows sure economic savings, thanks to virtual proofs obtained with the simulation.

In terms of saving thanks to simulation the customer can save time and resources avoiding empirical tests: the use of simulation software can help companies  cutting costs and reducing sampling phase as it allows to work on different variables before the production.

Choosing Zinc instead of other materials

With zinc die casting is possible to develop and manufacture a product with thicknesses and conformations that are not possible with other materials, without any secondary operation or additional components. In fact one of the most important benefit of zinc is its accuracy, zinc alloys allow closer tolerances than any other metal, aluminum or magnesium over all or molded plastic.

Zinc allows a higher casting fluidity than other materials, with it is possible to eliminate extra machining, scrap rates and cut costs, processes are faster and tool wear is minimized. In addition to this Zinc alloys can be casted with less draft angle than other materials, that is an advance during the moving mechanical process. All these steps are cost saving.

Regarding the maintenance of moulds, using low casting temperatures allows to extend life for die casting tools. In addiction maintaining a mould in good conditions enables a consistent saving due to scrap elimination and material waste.

Moreover is important to say that with zinc is possible to diminish the number of components in a product and diminish the weight, in a cost saving way.

In addition to this zinc allows to reach a better surface quality, in terms of sliding of other components, thanks to its smooth surfaces. It is hard to reach the same roughness rate with Aluminum die cast components compared to zinc, that is why very often secondary operations are necessary to reach the same target of smoothness. This means cost.

Optimizing products and processes means to create innovative and creative solutions together with customers.

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Value analysis/Value Engineering

Value Analysis is a standardized, multi-skilled team approach, which is aimed at identifying the lowest cost way and ensuring the highest worth to accomplish the functions of a product, process or service.

Joint Value Analysis/Value Engineering is the best way to pursue the long-term goal to establish good business relationships with zamak die casters: trust and open sharing of information and ideas are the basis of this kind of collaborations.

The supplier involvement during VA/VE can help a company save money and optimize a product design; in die-casting and metal injection moulding, it is possible to achieve lower costs, better performance, higher quality, and shorter time-to-market.

A fundamental part of Procurement strategy is to increase supplier involvement and collaboration in product improvement, cost reduction and enhancement activities. Informing and involving zamak die casters in VA/VE activities, therefore, can help clarify the process definition and encourage alternative proposals, resulting in more competitive price and/or better product.

Benefits of cost savings, process improvement, and transparent communication are shared between die casters and customers as the supplier can determine a calculated cost reduction, show quality improvement or scrap reduction; the customer benefits from open communication, cost reduction and/or better quality, and delivery within the deadline.

Zamak die casters involvement during VA/VE can lead to proposals for component design changes (materials or specifications, dimension or tolerances, components substitutions), manufacturing or assembly process changes (tests reduction, new process technology, part reliability), and logistics (reduced freight costs, packaging improvements, inventory management).

Product engineers are always trying to reduce production and material costs, maintaining at the same time the quality of products. Value Analysis / Value Engineering is fundamental to reach that goal.

A die casting company can save costs among three different fields, as we said above choosing the best material to meet the customer’s expectations, finding the best assembly process, and using a simulation tool to prevent any processing issues.

Choosing to use Zamak instead of aluminium, stainless steel or any other material can be the perfect way to save costs.

Zamak die casters can help reduce components for subassembly, leading to time saving both for parts control and for assembly process.

With simulation tools, the entire production cycle can be simulated: based on data resulting from the analysis it is possible to choose the best design and process to satisfy even the most demanding customers.

Value Analysis Check List

Here below a series of question to ask yourself during value analysis / value engineering. If and when in doubt, consult an experienced die caster.

1. Can more functions be fulfilled with a redesign of the component?
2. Are you using the material that will result in the most economical product?
3. Is it possible to reduce wall thickness?
4. After simulation, tests and comparison with competitors’ ones, is the component over engineered?
5. Is it possible to reduce material waste with different processes?
6. Are all tolerances strictly necessary?
7. Can minor design changes reduce machining operations?
8. Are surface finish requirements essential? Is it possible to use alternative finishing methods or optimize the design for the operation?
9. Can manual and assembly operations be totally eliminated / reduced / automated by design or process optimization?

Please feel free to share your experience in VA/VE and your suppliers’ contribution to such an important phase by contacting us with the form below.

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Optimizing die casting engineering

Die casting engineering optimization is not only related to simplify the process and cost reduction during different phases of die casting process, but also their integration with it.

For this reason integrated analysis models have a fundamental role during die casting engineering.

Technology, during the past few years, allowed to reach an important level in developing tools for design, production and control of the process: the aim was to made a complex structure where tools were in constant collaboration among them.

Productive plant, die casting tools, automation tools, cooling tools, and secondary operation tools are necessary to design a process that is similar to reality.

However often designers are tempted to obtain the optimal process for a particular product. In this way zinc die casting manufacturers do not consider physical limits imposed by usual die casting process and its tools.

The importance of simulation in cost reduction

Cost reduction in die casting engineering can be achieved widening simulation phase. In fact simulation is a key point of the process that is developed only at the beginning of industrialization of the product or component.

Every improvement adopted in this phase allows to reach an important saving during productive life of a component or product thanks to a small investment.

Integrated model in process simulation

Hereunder is explained an approach to integrate every phase of die casting process in simulation analysis.

Once the designer has decided phases that are going to be part of the productive process  uses simulation tools to optimize them and reduce costs and time.

First of all is important to consider different systems: the one that regards machine and the one that concerns die casting: at the beginning they compose the system hardware and they can be used for an iterative simulation of every phase of die casting process.

Step 1: A first design approach to moulds

In this step is important to define the mould from a mechanical and thermo-fluid dynamic viewpoint. Taking into consideration clients’ requests, component characteristics and critical points, the designer has to point out some rules to be followed in order to produce a correct and functional mould. First of all the designer has to reduce complexity of the mould, increase ratio between casting weight and waste materials and positioning gates near important areas for aesthetic or structural requirements.

Step 2: Define die casting machine

Considering mould dimensions and liquid metal thrust, the designer has to choose the type of machine that suits better the process.

At the same time when the designer chooses the type of machine, need also to consider the stroke diameters and working pressure.

Step 3: Simulation of this step

There are different kind of simulation that change related to different process phase analyzed. For example the first step that has to be studied with CFD method is filling the cavity. During next step other methods can be used such as CFD method for solidification of the metal, FEM analysis for casting ejection, automation software to handle components or casting, thermal analysis one or multi dimensional  for quenching. In every approach that the designer will choose, feasible boundary conditions must be identified with the aim of reaching an optimal state.

Step 4: Run the iteration or go back to the beginning

If the process simulated in this step is obtainable from the defined system hardware, the designer can move to next phase; if not the designer needs to go back to phase 1 and modify the mould or the machine choice.

Step 5: Entering the next phase

In this step new hardware such as cutting machine or cooling system can be added to the algorithm.

Step 6: Return to previous step

The iteration cycle restarts from step 3 and 4 and proceed to next process phases. After simulation, if the optimal condition is not reachable with hardware defined before, is necessary to intervene and go back to step 1.

Thanks to this integrated system, the process is optimized for every single step because at every iteration cycle the algorithm can change the hardware defined at the very beginning of the process.

Process stability

The aim of the previous algorithm is to identify an optimal cycle time that can be supported by the hardware system.

However to make the process stable, this is not enough. Variables of the system have physical limits that cannot be overtaken and that can be represented with a Cartesian coordinate system edges of a multidimensional solid. As long as the point that represents the productive process is inside the solid and distant from the edges the process is stable.

This process can be defined unstable if some part of the inside system such as thermos regulation machine do not reach the correct temperature indicated in its technical sheet.

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

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Casting process is composed of six phases:

• Die casting
• Elimination of runners and overflows
• Handling
• Surface treatments
• Packaging and delivering
• Controlling the process

Die casting

The best way for cost reduction, during die casting process, is to think about the production phase during the mould design, in fact reducing costs is an issue that must be approached at the very beginning of the project.

Designers have to focus on different aspects such as obtaining a functional product with aesthetical and technical characteristics required by clients, obtaining a low scrap rate and time cycle, reducing runner and overflows weight, decreasing mould and die casting machine wear.

Furthermore is important to consider that there are many conditions that follow or precede casting phase that are bounded to it. For example is fundamental to estimate quantities of material to be produced to create a mould with the right number of cavities. If this number is underestimated the company cannot satisfy clients’ orders, and could be forced to use machines for a longer time or to create a new mould; if the number is overestimated the production deals with a more complex mould than was needed with a consequence of higher risk of producing scraps.

Elimination of runners and overflows 

This phase regards cooling, elimination of sprues and positioning components for handling.

It is really important to decrease the time of this phase that is lower than the one of die casting; on the other hand is necessary to foresee a buffer where components are accumulated to be processed in a second time.

Cooling phase has a central role in reducing time. With quenching, for example, many ways are possible: changing the type of fluid its temperature and its status that can be static or dynamic. In fact if the fluid is static it takes more time to cool down the component, if not quenching is quicker because speed increases the heating transfer.

To avoid secondary deburring and finishing is necessary to design an automatic process of runners and overflows elimination, that allows to obtain finished or semi-finished components ready for secondary treatments.

Using an automatic system also to position parts for handling allows to cost reduction in terms of time and manufacture. 

Handling

Often the designer does not consider handling phase important, but it can be a tough problem at the beginning of mass production.

In particular considering dimensions, weight and aesthetic qualities requested is important to foresee a system that minimizes time, dimension of containers, positioning and handling components inside them.

Is important to avoid shock, in particular with high aesthetic quality requested, waste of space and lead time too long. A just-in-time process allows to cut stocked materials and in this way is possible to obtain a cost reduction in casting process. In this case is fundamental to consider organizing flows as well as design.

Surface treatments

Surface treatments cycle need to be designed and optimized with the aim to produce finished product requested by clients. Often is the client that imposes different steps of the cycle, otherwise is the designer that can choose them. In this case the first phase of the cycle is dedicated to polish components and can eliminate marks created during die casting process such as part lines.

Then the component has to be prepared for the real surface treatment and linked to the type of treatment the designer will choose the best solution for it: degassing, sand blasting and deburring can be part of this process.

Packaging and delivering

Also in this phase, such as during handling phase, design characteristics of components have to be considered. Packaging and delivering are fundamental because they are the first elements that clients see. Package volume and time are principal aspects that need to be optimized for cost reduction. The first one need to be reduced without touching the external integrity of the product; while the second one decreases when the packaging allows a quicker insertion and extraction.

Controlling the process

This step crosses every aspect of the entire die casting process and it regards its steadiness.

It is really important to be focused on this phase to avoid non-compliances. Controlling can be operated in two different ways: firstly recording parameters and handling them during the process, secondly is necessary to operate sorting actions to prevent delivering of non-compliances components that are caused by uncontrolled parameters.

For other content related to cost reduction in zinc die casting process read Cost reduction in zinc die casting. To be updated on trends and innovations in the Zinc Die Casting industry, you are welcome to subscribe to our blog.

Our technical staff is available to support your designers’ inventiveness and to develop innovative and creative solutions together, in case you need any further information, please get in touch.

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There are different areas where designers can save:

• Material
• Tooling
• Casting
• Trimming
• Machining
• Surface finishing
• Assembling
• Packaging for delivery

Material

The cost of zinc alloy material in a raw way depends on the weight of the casting and obviously on the price of the alloy per ton. Normally is possible to lose metal about 5% during the casting process. To avoid waste of material given by overflows and runners is necessary a good design and a good process. This reduction shorten melting loss costs and less melting energy means less CO2 production.

Regarding the cost of material it is impossible for casting buyers to predict it. Normally this kind of alloys are sold linked to the price of zinc given by the London Metal Exchange at the moment of buying. For this reason costs of all the raw materials change and it’s impossible to predict them. In fact the only solution possible is to make comparisons based on average prices of the past months and on future trends. For the die caster the cost of raw material is an important part of the process costs. For this reason die caster needs to control at regular intervals during the production the price to avoid rising costs in production.

Tooling

The price of tools affects the good success of the casting process. Of course the price of tools depends on the degree of their complexity and precision that depends on the design of the casting that is required. A right product design allows to have a less complex so less expansive mould that helps to save in economic terms. Another problem regarding die tools that affects cost reduction is that die tools are vulnerable to deterioration and failure. During die casting process the heat that goes from the molten metal to the die causes a phenomenon called die wash that is die steel erosion. Loss of sharp definition, deterioration of the surface quality and thickening of some sections are the most clear visual effects of the die degeneration. To minimize costs, related to such wearing of the tool, is important to do extraordinary maintenance like cores refurbishing or substitution.

Compared to other alloys zinc can provide a better die life and lower maintenance costs, the typical die life might be around 1 million shots, much more than aluminium (200,000) and magnesium (400,000) ones. Furthermore moulds in zinc die casting allow a large amount of shots, however to guarantee the productivity is advisable a backup mould to allow correct maintenance activities of the mould that ensures a smooth production process.

Casting

Zinc alloys productivity is higher than the one of aluminium and magnesium. The most common used zinc alloys can be produced by hot chamber process that is faster compared to cold chamber process, commonly used for Aluminum HPDC .To achieve higher speeds of die casting process is useful to improve the process parameters such as temperature, injection speed, filling time and cooling time. The key element of keeping costs down is an uninterrupted production of castings. In terms of die casting production there are different way of producing components for die casting machines:  automatic or semi-automatic way. If the machine operates semi-automatic the operator removes the complete shot from the die, if instead it is an automatic production the die cast can be removed by a robot. Moreover automatic production is normally used to produce a large volume of manufacture. The high automation level allows important savings, is possible to have second operations close to die casting machines and integrated with it through robots.

Trimming

Trimming is the process of removing the die castings from runners and overflows. Zinc die casting process often allows to avoid trimming operation with thin gate areas and less overflows.

The casting can be produced without flash and the runners can often be removed with a barreling operation. Breaking the runners saves the cost of a press and a trimming tool; furthermore the barreling operation is more cost saving than press trimming.

To remove at the same time the runners and the flash it is possible to use a press trim tool that will cost around a 10% of the cost of the die. It is a metal shearing operation.

This kind of tools are manually operated in low quantity production, with high volume production the trimming tool works in line with the die-casting machine. It is important that the casting designer ensures that the features are not vulnerable to damages otherwise the casting will be rejected.

In this case this press trimming operation has the same cost as other die casting alloys.

Machining

Machining on zinc casting is required to produce features that cannot be cast such as inner threading or complex features on parts at low quantity demand. In terms of saving in a large production it is possible and convenient to make moving die elements while in a lower quantity production a mold with complex moving elements will affect the costs.

Zinc die casting alloys can ensure a better quality in a saving way. In terms of machines in fact the one used in zinc die casting are faster and can avoid loss of time and money. Compared to other materials zinc has the advantage of accuracy in terms of datum surfaces provided for clamping.

Surface finishing

Surface finishing can affect costs in a large or small proportion depending on the aims above described.

The most expansive finishes are the one that demand a large amount of manual work; if these costs are really high it is important to focus on maximizing the castings suitability. Therefore is important that the die caster and the finisher work as a team to reach clients’ expectation and create a perfect and functional product.

Assembly

Assembling costs are affected by the amount of work that is required and the tooling and equipment that are needed to complete the process. Zinc die casting alloys allow designers to apply cost effective procedures such as automatic assembly.

Packaging for delivery

If the component has been given a high finish needs to be transported in a way to prevent each components any problem; otherwise if the product has a normal finish it can be delivered without any separation in cardboard boxes.

There are also other possibilities when it comes to save during the die casting process, if you want to discover more read Cost reduction in zinc die casting.

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

Our technical staff is available to support your designers’ inventiveness and to develop innovative and creative solutions together, in case you need any further information, please get in touch.

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