FAR使用仿真技术选择合适的压铸机来提高生产率及利润率

自1992年以来，FAR一直在汽车行业中发挥着积极作用，不断的创新技术。FAR始终以可靠和积极的态度服务客户，希望利用最好的技术在压铸过程中提供专业知识、更好地规划和解决各项难题。因此，当客户要求FAR增加汽车的油泵产量时，FAR需要寻求更先进、更有效的解决方案。

FAR  had been successfully producing this automotive oil pump on a  single-cavity die using a  Colosio  560  tons die casting machine  (DCM). When their customer challenged them to increase production volumes,  the obvious thought was to switch to a  double cavity die.  In doing so,  however,  they would need to keep costs low while,  at the same time,  maintaining the same high-quality castings.  For that reason, choosing the best DCM was imperative.

The standard approach, using empirical evaluation, showed the necessity to use a 1000t-1200t DCM to produce this oil pump on two cavities – but the challenge for FAR’s technical & management teams were to manage with a smaller, more cost-effective 750t DCM. Also, to meet final quality requirements, FAR elected to use High Vacuum on the double cavity die, sharply decreasing air counterpressure during filling, to prevent gas porosity problems and reduce the injection force.

ESI collaborated with its partner ECOTRE Valente SRL to develop a new solution for FAR: a virtualized die casting machine integrated into the ESI ProCAST simulation software to account for the hydraulic injection force of the DCM controlling the piston movement during filling, as it would in real-time. The optimized piston speed profile could then be exported from simulation directly onto the DCM PLC system.

Ultimately, the simulation allowed FAR to optimize the gating and evacuation system of the double cavity die, making it suitable for the 750t machine. The vacuum system further reduced the required hydraulic injection force. With ProCAST, FAR identified the right DCM to produce a prospective cast part, ultimately reducing their parts cost by 28%. In addition to this, an estimated operational cost of 165k€ is saved per year, due to the virtual machine selection of Colosio 750 ton instead of Colosio 1200t machine.

Our current and long-term goal is to be an always more reliable and proactive “high-tech” partner for our clients.
Our primary mission is to satisfy our clients in terms of products and service, offering our expertise in the die-casting process and ensuring a close cooperation aimed at better planning and problem-solving. In order to achieve our goal, our concept of business has changed over the years becoming the key element of our company, entailing moral and ethical obligations towards our stakeholders (employees, clients, suppliers…), towards the environment and, not least, the State. Every time we take a step forward, we are already focused on the next two.

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