Cutting Costs in Designing a High Pressure Die Casting Process

For some companies, cost, quality, and speed are three factors in a dynamic equation that forces their customers to make choices they don’t want to make.

For example, a company can tell their customer that if costs remain constant, speed must be increased and solution quality must be reduced to compensate. Similarly, if the customer says that costs have been reduced, the company may tell them to reduce quality or speed (or both) in order to reduce prices.

However, many consumers are not willing to make those sacrifices to lower prices. They want everything.

The question is: is it possible? Can a company produce fast, high-quality castings and keep costs down at the same time?

The answer is no – at least if we continue doing business as we always have. Something will change – but what?

Until recently, much of the high-pressure die casting process was done by ‘trial and error’ – and a very tried and tested method – but this can increase costs, limit quality and delay production. Unfortunately, some projects are so complex that using ‘trial and error’ means that quality solutions are never produced. The end result is solutions that don’t meet the customer’s needs and cost the die caster a lot of money.

MAGMASOFT – Process simulation software tailored to the specifics of the high pressure die casting process helps eliminate ‘trial and error’ uncertainties and gives the die caster a clear picture of what to expect in the die design and casting process. With this software, engineers can simulate, understand, change and optimize casting conditions china die casting supplier.

Available in the market for over 20 years, Die Caster uses modern process simulation software on a daily basis. The first simulations are performed as part of the quotation process to gain a better understanding of the project. After winning the bid, the die design is simulated. The feed and overflow system as well as the cooling and heating channel positions can be varied until a good solution condition is demonstrated. Potential weaknesses can be determined, corrections made, and simulations repeated until the customer’s goal is met—before any fixes are ever made. Using simulation today’s engineering process is much faster, the quality of the solution is higher, the cost is lower – and the customer gets the quality, price and speed they need, and better delivery to the die caster – and a happy customer.

However, justifying the cost of simulation software is not an easy task. Determining the cost while the die is in the machine and the process generates a high scrap rate is one thing – but understanding the solution cost when using simulations is much more difficult. In general, it is easy to estimate die-casting machine and hourly operator costs. Tracking the cost of each die-casting machine’s melt or use of oil, electricity, water or spray fluids is more difficult, especially when they are not used for production. After all, if you can get the right solution with simulation, not only will those initial production costs be fixed – but you might also forget about the money you save. Similarly, dollars not spent on wages for engineers, maintenance workers, and machine operators who do not have to produce low-quality castings are difficult to justify.

By jamesmonica839

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