Our solutions for your OEE
Your success is driven by the number of good parts at the end of the shift
And the die has the biggest impact on it.
Cycle time
The thermal balance is crucial
Together with you we define the optimal cycle time.
Your input:
- Dry-cycle time of your die-casting cell
- Cooling system (media, number of circuits, flow volume, temperatures)
- Spray system (standard, minimum volume, oil mist)
- Casting geometry
Our contribution:
- Optimized runner system
- Calculation of energy inputs and outputs as basis for an optimal cooling design (DieTherm methodology)
- Structure of the active cooling elements
- Validation by cycle simulation
Your benefit:
- Achieve the optimal cycle time with your die-casting cell right from the beginning
- No compromise on quality and die life
- Existing cycle-times can often be reduced by more than 20%
Up-time
After cycle time optimization, improving plant utilization usually offers the most potential benefit. In the production of complex castings, problems with the die are often the leading cause of production stoppages. Therefore, Schaufler Tooling has developed numerous solutions to minimize downtime.
Die Mounting / Change
- Quick change of slides on the die-casting machine; <10 min from shot to shot are possible
- Patented quick change of die inserts with ejector system for compact castings such as engine blocks, developed by Schaufler Tooling
- Leak- free plugs for cooling holes: guaranteed over the entire insert life
Die-spitting / Dimensional Deviations
- Patented spit-stop to prevent spitting/metal flakes, developed by Schaufler Tooling
- Mold centering and slide lock systems, developed by Schaufler Tooling, now in use in more than 200 molds
Die Steel Chipping
- Fast exchangeable cores and partial inserts
Quality
Even once reasonably well-functioning production has been established, improvements in quality can be used to minimize waste and rework rates.
We contribute to this by:
- Organization and Implementation of joint optimization workshops
- Analysis of potential and actual casting defects and development of solutions – among other things, we perform very precise and detailed simulations for this purpose
- Vacuum support or Vacuum-casting with sealed dies
- Exact design and placement of squeeze-pins where required
- Jet cooling
- Additive manufactured contour parts and partial inserts
