How Jet Cooling can boost your Profits without investing a bomb even when your team has zero experience with it?
“To optimise output, I would invest in peripherals and automation rather than putting another Die casting machine which produces scrap parts,” said the President of a fastest growing die casting company.
Post Covid-19, demands for automotive have been fluctuating. The emerging Electric Vehicle mobility is disrupting faster than expected.
Die Casting, largely dependent on the automotive sector, has been the biggest supply chain ingredient.
The challenge is to keep the die casting sustainable and profitable too.
Light weighting has further brought in thin and complex castings, critical to die cast.
Every caster is preparing itself to be equipped with technology and processes to enable them to manufacture critical castings.
The big question is “Are You?”
Profits with lower rejections
A customer in Taiwan had a 10% rejection rate in the engine block with level 3 & 4 shrinkage porosities. Deploying the RAGA NEX 100 Pins Jet Cooling with a closed-loop system, the rejections came down to just 2%.
With Jet Cooling, parts like bedplate, cam carrier, rocker arm, cooler cover, Timing case cover, ETB Housing, Clutch cover, Crankcase, Case oil pan, Transmission case, TransAxle, Filter housing, brake oil cover had rejections coming down from staggering 35% to less than 2%.
Less scrap and no melting losses makes HPDC profitable.
Profits by eliminating processes
With jet cooling of core pins and thin sections, ejection drafts have come down.
This has helped die casters eliminate post-casting processes like drilling or finishing operations.
Less processes cost less.
Profits by lower consumable cost
A customer was facing breakage of core pins after 2000 shots.
Had similar issues for pins in the gate area that were exposed to high thermal impact.
The mold got modified to incorporate jet cooling. Life of these pins increased by over 3 to 5 times.
The customer now saves on consumable cost per shot and is competitive.
Profits by decreased breakdown time
Pin breakage, wear and soldering are reasons for production halt for doing maintenance or changeover.
Customer pays shot rate in the part price. Production stoppage means wasteful burning of fuel, unutilised manpower & resources and delayed deliveries.
High life core pins or jet cooling are a direct contributor of profits.
Brands you as a high technology manufacturer
With increasing casting complexities, OE customers are looking for casters equipped and experienced with technology.
Jet cooling is a worldwide accepted technology. Die casters are making jet cooling as part of the Die Casting machine package.
Ahead of your competitors
Speed is the new currency to be ahead of the competition.
Speed of developing the right quality part in one go.
Challenging but technologies like jet cooling and vacuum help a lot.
Readiness for higher margins parts
Die caster aims to produce castings with higher margins.
These are castings which are critical and need specialisation.
Jet cooling helps you produce such value-added parts. Increase profitability on both shorter and longer runs.
If Casting rejections is a concern for you, we would be glad to share with you our experience dealing with them, click here.
