Die casting processes are nowadays widely used in the industry and differentiate from metal casting from the high-speed and pressure applied to inject the metal into the cavity. Due to this procedure, the produced parts manage to acquire better mechanical characteristics, dimensional precision, and smaller roughness. Due to the automation possibility, and mould coating possibilities, the process becomes cost competitive at significant production rates. However, to assure proper functioning and extended life of die casting equipment, it is necessary to continuously control the process variables, undertake maintenance, and implement process improvement actions to the production lines. The objective of the present work is to improve the efficiency of a Zamak die cast injection line for cable terminals used in Bowden or control cables for the automotive industry. By reducing wear and number of failures of standard components in this production line, and thus by diminishing the stoppage and replacement costs, it becomes possible to improve the current process. By applying specific improvements to the injection subset, heating element, and pump, including geometry modifications to the injection elements and respective interactions, heat treatments, higher power resistor, and groove/ring system in the pumps’ piston, a significant process improvement was accomplished by the proposed and tested modifications, leading to reduction of failures and operational costs, and consequently higher competitiveness of the process.
KhanMAASheikhAKAl-ShaerBS, et al. Evolution of metal casting technologies—a historical perspective. Berlin: Springer, 2017.
2.
RaoTR.Metal casting: principles and practice. Dehli: New Age International, 2007.
3.
VinarcikEJ.High integrity die casting processes. Hoboken: John Wiley & Sons, 2002.
4.
Ajay KumarPRohatgiPWeissD. 50 Years of foundry-produced metal matrix composites and future opportunities. Int J Metalcasting2020; 14: 291–317.
5.
KrishnaEDGShamshoddinSRajuD, et al. Effect of cooling pattern on centrifugal casting mold stress–strain distribution through computational fluid dynamics and finite element method analysis. Proc IMechE, 2018; 232: 4357–4370.
6.
AziziAGheiratmand HaghighiGBahramiP, et al. Comparison of ZAMAK 2 and ZAMAK 3 alloys produced by powder metallurgy process. J Mod Process Manuf Prod2021; 10: 45–58.
7.
Martinez PageMAWeidenfellerBHartmannS.Influence of temperature and aging on the thermal diffusivity, thermal conductivity and heat capacity of a zinc die casting alloy. J Alloys Comp2019; 786: 1060–1067.
8.
GrooverMP.Fundamentals of modern manufacturing: materials, processes, and systems. New York, NY: John Wiley & Sons, 2020.
9.
SilvaFJGCampilhoRDSGFerreiraLP, et al. Establishing guidelines to improve the high-pressure die casting process of complex aesthetics parts. Transdisciplinary engineering methods for social innovation of industry 40. Amsterdam: IOS Press, 2018, pp.887–896.
10.
AnandANagarajanDEl MansoriM, et al. Integration of additive fabrication with high-pressure die casting for quality structural castings of aluminium alloys; optimising energy consumption. T Indian Met2023; 76: 347–379.
11.
DourGDarguschMDavidsonC, et al. Development of a non-intrusive heat transfer coefficient gauge and its application to high pressure die casting: effect of the process parameters. J Mater Process Technol2005; 169: 223–233.
12.
RingenGWeloTBreivikSM.Rapid manufacturing of die-casting tools - a case study. Procedia CIRP2022; 107: 1565–1570.
13.
KwonH-JKwonH-K.Computer aided engineering (CAE) simulation for the design optimization of gate system on high pressure die casting (HPDC) process. Robot Comput Integr Manuf2019; 55: 147–153.
14.
NiuZLiuGLiT, et al. Effect of high pressure die casting on the castability, defects and mechanical properties of aluminium alloys in extra-large thin-wall castings. J Mater Process Technol2022; 303: 117525.
15.
HaraldssonJJohanssonMT.Review of measures for improved energy efficiency in production-related processes in the aluminium industry – from electrolysis to recycling. Renew Sustain Energ Rev2018; 93: 525–548.
16.
PintoHASilvaFJGMartinhoRP, et al. Improvement and validation of Zamak die casting moulds. Procedia Manuf2019; 38: 1547–1557.
17.
KohlheppMUggowitzerPJHummelM, et al. Formation of die soldering and the influence of alloying elements on the intermetallic interface. Materials2021; 14: 1580.
18.
WangYWuSXueX, et al. Experimental and numerical study on formation mechanism of linear macro-segregation in low-pressure die casting of Al–Cu–Mn–Ti alloy. Proc IMechE, 2017; 231: 1946–1955.
19.
KhanFIHaddaraMM.Risk-based maintenance (RBM): a quantitative approach for maintenance/inspection scheduling and planning. J Loss Prev Process Ind2003; 16: 561–573.
20.
FerreiraSSilvaFJGCasaisRB, et al. KPI development and obsolescence management in industrial maintenance. Procedia Manuf2019; 38: 1427–1435.
21.
AmaralFD.Gestão da Manutenção na Indústria. Lisboa: LIDEL, 2016.
22.
PintoGSilvaFJGBaptistaA, et al. TPM implementation and maintenance strategic plan – a case study. Procedia Manuf2020; 51: 1423–1430.
23.
Veres (Harea)CMarianLMoicaS, et al. Case study concerning 5S method impact in an automotive company. Procedia Manuf2018; 22: 900–905.
24.
GulatiRSmithR.Maintenance and reliability best practices. New York, NY: Industrial Press, 2009.
25.
MoubrayJ.Reliability-centered maintenance. New York, NY: Industrial Press, 2001.
26.
PintelonLParodi-HerzA.Maintenance: an evolutionary perspective. In: KobbacyKAHPrabhakar MurthyDN, (eds) Complex system maintenance handbook. London: Springer, 2008, pp.21–48.
27.
MartinsLSilvaFJGPimentelC, et al. Improving preventive maintenance management in an energy solutions company. Procedia Manuf2020; 51: 1551–1558.
28.
OnawumiASAremuAAjibosoOA, et al. Development of strategic maintenance prediction model for critical equipment maintenance. Mater Today Proc2021; 44: 2820–2827.
29.
ChengGLiL.Joint optimization of production, quality control and maintenance for serial-parallel multistage production systems. Reliab Eng Syst Saf2020; 204: 107146.
30.
ShankerHWattalR.A comprehensive survey on the cold metal transfer process in welding similar and dissimilar materials and for cladding. Proc IMechE, 2023; 237: 2360–2391.
31.
IshikawaK.What is total quality control? The Japanese way. Hoboken, NJ: Prentice Hall, 1985.
KogawaACSalgadoHRN. Quality tools for a successful strategic management. Int J Bus Process Integr Manag2017; 8: 153–159.
34.
GürelE.SWOT analysis: a theoretical review. J Int Soc Res2017; 10: 994–1006.
35.
DysonRG.Strategic development and SWOT analysis at the University of Warwick. Eur J Oper Res2004; 152: 631–640.
36.
KarimiMNiknamfarAHNiakiSTA. An application of fuzzy-logic and grey-relational ANP-based SWOT in the ceramic and tile industry. Knowl-Based Syst2019; 163: 581–594.
37.
CharltonR.Threaded fasteners: part 2-fundamentals of threaded fasteners, friction and lubrication effects, installation methods, guidelines and corrosion upgrading. In: NACE CORROSION, 2012. NACE.
38.
PereiraJLTACampilhoRDSGSilvaFJG, et al. Improving the efficiency of the Bowden cable terminal injection process for the automotive industry. Processes2022; 10: 1953.
39.
NotzonS.High pressure dynamic seal for plunger pumps with pressures above 35 KPSI. In: ASME 2010 pressure vessels and piping division/K-PVP conference, 2010, pp.111–119.
40.
CamposUHallDMatthewsJ, et al. Overview of the geometric parameters of a press-fit interlocking mechanism: experimental and FEA analysis of steel pipe joint. In: Pipelines2018, 2018, pp.406–414. Reston, VA: American Society of Civil Engineers.
