Process Control and Improvement

<<< Die and Process Design

Without measurement there can be little improvement.

These subjects will teach you the correct way to measure all aspects of the Die casting process and how to present and analyse the data.

Some key process controls and post casting operations are also explained.


Measuring the Die Casting Process

MeasuringHeader200Hand-held and Simple Instruments
Since all the action in the Die Casting process takes place deep inside solid steel dies, the process must be measured indirectly. This module explains what to measure, how to measure it and how to present the data. Metal temperature, Bulk Die temperature, Die Surface temperature, Casting Ejection temperature, Tie bar force and data logging are all explained in detail.

Machine Shot Monitors
Since all the action in the Die Casting process takes place deep inside solid steel dies, the process must be measured indirectly.  This module teaches how traditional machine based shot monitors can be used to measure key aspects of the process and the operation of the Die Casting Machine.

Advanced Shot Monitors and Sensors
This module covers the full range of measurements that can be made using advanced shot monitors and sensors placed strategically in the dies.


Furnace Technologies

FurnaceHeader200This subject covers the different types of furnaces available for melting Die Casting alloys. Calculations on fuel use, efficiency, optimum throughput rates and recovery times enable a technical analysis to be made.

Holding furnaces and launder systems are also covered. 

Ways to measure furnace efficiency, and to pinpoint areas of potential improvement can lead to big savings in energy costs. 


Release Agents and Lubricants

ReleaseHeader200Although commonly used in the Die Casting process, not many people really understand how they work, how to check the specifications and how to use them effectively.

As a result, there is a lot of waste in many plants, and a lot of opportunity for improvement.

This subject covers testing, selection and maintenance of release agents, sprayers, nozzles, dosage devices, reciprocators, water based, oil based and wax based release agents.

Different types of die and machine lubricants are examined, along with their strengths, weaknesses and most effective applications.                                          


Die Temperature Control

TempControlHeader200Compares and analyses the various options available to remove the heat from each shot and maintain a stable die temperature. Manual and instrument based methods to calculate heat flows are examined along with equipment specifications and cooling water conditioning.

   

                                                                     


Heat Treatment of Die Castings

This module examines the ability and techniques of modern heat treatment processes to improve the properties of Die Cast parts. Specifications and test results are emphasised.

                                                                        


Costing of Die Castings

In many organisations, the costing system is maintained and controlled by accountants and managers. Yet for Die Cast parts, the actual costs of production is heavily influenced by the decisions and actions of technicians and engineers.  This module covers the techniques of estimation, running cost calculations, amortisation of costs and the effects of production volume on profitability and costs.

                                                                      


 

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