Smart Speed: Enhancing Die Casting Efficiency Without Sacrificing Quality

ELK GROVE VILLAGE, IL, May 30, 2024

Just as rushing through a red light might shave a minute off your commute only to lose a half-hour to a traffic ticket, optimizing die casting cycle time demands a careful balance between speed and maintaining quality standards. 

In the world of die casting, efficiency is often linked with faster production times. Yet, the drive for the shortest possible cycle can inadvertently introduce inefficiencies and quality issues, ultimately decelerating overall production.

So, how can optimizing die casting cycle time focus on more than just speed, aiming instead to enhance the entire production process holistically? This article will delve into strategic approaches to balance efficiency and quality effectively, ensuring sustainable manufacturing practices that avoid the pitfalls of speed.

Understanding Cycle Time in Die Casting

The die casting process comprises several critical phases: die closing, injection, cooling, and ejection. Each phase must be precisely controlled to maintain the quality of the final product. 

The common misconception is that reducing the time of one phase—like shortening the spray cycle or reducing drying time—will proportionally decrease overall cycle time. However, this is not always the case.

The spray cycle in die casting involves applying a water-oil mixture to cool the die and lubricate it for the next cycle. Attempting to save time by skimping on this process, such as not fully blowing off excess water or reducing drying time, can lead to significant issues. For instance, premature drying can cause porosity, resulting in more frequent stops and higher scrap rates. Each "shortcut" must be evaluated not just for its time savings but for its impact on the entire cycle and product quality.

The Power of Technology Integration

Shibaura Machine's TOSCAST system is a pivotal tool in the management of die casting cycles. It displays individual segments of the cycle, allowing operators and process engineers to pinpoint where adjustments can be made without compromising the integrity of the die or the quality of the cast parts. For example, a slight reduction in die close time might seem beneficial but can cause the dies to misalign or damage if not properly timed.

Furthermore, leveraging data analytics through the IIoT solution machiNetCloud provides a broader perspective. This technology records cycle parameters and downtime, providing a comprehensive view of how changes affect long-term production. It's not just about making the cycle faster but making it smarter.

Integrating machiNetCloud with the TOSCAST can lead to substantial improvements in efficiency. For example, saving a second in the spray time might appear to speed up the cycle initially, but if it results in an hour of downtime per shift due to increased soldering, the trade-off is counterproductive. By harnessing the TOSCAST 888's capability to monitor and control individual cycle segments, alongside machineNetCloud's ability to provide long-term insights, it's possible to achieve faster cycle times without suffering these adverse effects.

Innovative Die Casting Solutions

With advanced tools like the TOSCAST 888 and the analytical power of machiNetCloud, manufacturers can achieve a balance that maximizes productivity while maintaining high standards of quality. The goal is smarter, not just faster, production cycles that lead to better outcomes across the board.

By understanding the comprehensive impact of each cycle component and utilizing advanced technology to monitor and adjust processes, companies can avoid the pitfalls of partial optimizations and achieve sustainable improvements in their die casting operations.

Contact the Shibaura Machine die casting team to learn more about how the TOSCAST controller empowers manufacturers to maximize die casting potential.

• Phone: (888) 593-1616
• Email: dc-sales@shibaura-machine.com 

Achieving manufacturing excellence has never been easier.