Cost reduction is one of the key goals in the die casting process. Die casters employ numerous methods in each stage of the casting process in order to make it most cost effective without compromising on the quality of the component. Mostly, these methods are limited to specific aspects of the casting process and are not utilized fully.
Effectively reducing the costs involved in casting is possible only by applying these techniques to all the important phases of the die casting process. Utilizing the techniques on the stages from casting to the finished product will guarantee the best result in terms of cost and quality. Described below is how cost reduction methods are used in each stage of die casting.
Mold Design
Mold design is the first and most crucial stage of the entire die casting process. Cost reduction is most applicable from the very first stage of the die casting process. The product is finished and crafted with all the necessary aesthetic and functional characteristics that are needed by the clients. Some of the techniques to enhance the functionality of the process include getting low scrap rate, minimizing runner, and overflows weight as well as reducing machine wear and mold.
Eliminating Runners and Overflows
The other stage where cost reduction techniques are applied is in the elimination of runners and overflows. This stage is particularly concerned about the cooling, removal of sprues as well as the positioning of the components. This phase must require the lowest time than the previous stage and is made possible by changing the cooling phase such as by using static or dynamic fluids. An automatic process of eliminating runners and overflows are also created to prevent any secondary deburring and finishing.
Handling
Handling is an important phase especially if the product is intended for mass production. The system must be maintained is such a way to reduce the time, container dimensions, positioning, and handling of the components in accordance with the dimensions, weight, and other aesthetic properties of the component. By using a just-in-time process the stocked materials can be cut out, which can help in reducing costs in the casting.
Surface Treatments
The surface treatment is utilized for obtaining finished products as requested by the clients. This stage involves polishing of the components that can remove any of the marks or other smudges on the surface during the casting process. Degassing, sand blasting, and deburring are some of the methods involved in this step that will help in obtaining good finish on the material.
Packaging and Delivering
Packaging and delivering is another important step that ensures cost reduction in the process. During this, the design characteristics of the components are also carefully considered. Moreover, the necessary optimization for cost reduction is determined by the package volume and time.