Manufacturing Productivity Increase by Innovative Die Design in High Pressure Die Casting

For many years, zinc alloy parts have been produced in traditional dies by conventional high pressure die-casting methods. Companies with insufficient production capacity had to invest in new machinery to meet increasing customer demands. However, with current technological developments, there are new ways to increase production capacity using the existing machine line. The aim of this study is to increase the production efficiency in existing die casting production lines and to eliminate the quality problems experienced in our zinc alloy casting parts. The die system we designed for is an innovative die that allows injection from multiple points into the die cavity different than our traditional die designs. Thanks to the modular and flexible die developed within the scope of this study, it was possible to increase the production capacity of die casting machines by 50%. Thanks to the runner design we developed; we achieved satisfactory quality characteristics in the parts we produced. Additionally, we also achieved a significant reduction in energy costs which led to a much more competitive production for the company.