In recent years, foundries have been facing continuously growing pressure from their customers in the automotive industry to increase the final quality of the component and to reduce costs. The second highest costs in the whole process are productivity related, driven by cycle times. Therefore, BENEŠ a LÁT had decided to optimize their production by optimizing the cooling system in a low pressure die with MAGMASOFT®. The results from the simulation software have been proven by practice and led to a remarkable reduction of the cycle time.
Instead of using the old-fashioned trial and error method based on numerous and costly experiments, BENEŠ a LÁT engineers decided to use a far more predictable way of optimization. A virtual Design of Experiments using MAGMASOFT® was applied to search for an ideal set up of process parameters to control individual cooling lines, i.e. time of cooling and flow rates of the cooling medium.
The crucial point in the desired production cycle reduction was not only about finding the right process conditions. It was obviously just as important to maintain the casting soundness at the same time.
A first analysis of the original process layout was performed to verify the process parameters used in series production. The basic simulation revealed that the process parameters and the time until ejection were designed very precisely and left no room for shortening the cycle without impacting the heat balance of the die. The total closing time of the die was 460 s.