The Concept Of Die Casting Mold Qualification Rate
Die casting mold qualified rate is a system concept, from die casting machine edge, die casting initial inspection, cleaning, post-treatment, machining, transportation, and other aspects of the qualified rate belongs to the composition of die casting qualified rate, which is also called straight through rate. For example, the problem of equipment, the problem of mold, the problem of spraying, and so on, the problem of these points has a significant impact on the qualified rate of die casting machine edge, the failure of equipment and mold will increase the number of cold mold parts; the instability of equipment and mold will increase the number of defective products of automatic identification, the unreasonable heat balance of mold and spraying will increase the appearance defects of castings.
Die casting machine edge waste is the biggest part of die casting qualified rate scrap proportion, and also one of the biggest hidden points of die casting cost.
Today we will discuss the qualified rate refers to the qualified rate of machining, mold circles often said the qualified rate is generally referred to in this data. Machined casting material waste is still attributed to the defects of die casting, there are often defects: porosity, shrinkage, leakage, inclusions, deformation, black skin, bruising, etc. The most important defect is the problem of gas shrinkage and leakage, which is also the most difficult to solve and continues to repeat. Die casting pass rate of 95% is a value that can be reached, as long as the die casting company has the basic management process and standard, excellent mold tooling, plus an excellent die casting process and continuous improvement team, 95% of the die casting pass rate is not difficult to achieve, in the real production process there are many cases in the mold is good enough under the premise of 95% pass rate is easier to achieve.
However 99% pass rate is another concept, this discussion is a symbolic value, it represents a higher, more sustainable, and stable pass rate standard, it may be 97%, may also be 99.7%, the ultimate requirement is how we can pursue to excellence, it is how to step by step reality.
How Does A Die Casting Mold Company Need To Do To Achieve A 99% Compliance Rate?
CAMEL mold manufacturing process includes the following ways
Establish a project team
A high-standard project team is led or vice-led by the top management. As a senior manager, you must personally lead the core team through a few typical projects and then work together to develop effective processes and standards.
It is important to set a high target pass rate according to the difficulty of the casting.
Goal decomposition and division of responsibilities
Goal decomposition and division of responsibilities are particularly important, most of the problems that arise later are caused by the lack of comprehensive and careful analysis in the early stage; most of the implementation is not in place because of unclear responsibilities. Therefore, for the division of responsibilities must be designated the relevant responsible person, we must have more than one person to discuss the basic knowledge of a responsible, each thing is ultimately responsible for only one person. To avoid the emergence of localism and empiricism, and to designate the corresponding project management personnel to supervise.
Casting feasibility analysis - DFM (ideally simultaneous design)
Casting feasibility analysis is the most basic work because now many casting design engineers do not understand die-casting, the design of the casting is difficult to fully meet the process of die casting.
Die casting problems and effective communication with customers (to solve the difficulties or apply for relaxation of standards)
The feasibility analysis report of the casting is done is actually just the beginning, how to communicate effectively with the customer is very important.
Mold design (pouring system design, heat balance system design, mold flow analysis, structure design, DFMEA)
If you want to design a pouring system with a high pass rate, you should use the idea of process compensation to design the pouring system, which may increase the cost of post-processing, but it is worthwhile.
Design of thermal balance
Thermal balancing systems require strong logistical support, mold repair resources, and management capabilities.
Mold review (checklist check)
All important nodes in the process need to do the review, the review of mold design is the top priority, the key problems of solution A and alternate measures program B.