Top Die Casting
Case History #2 - Top Die Casting: this prominent Midwestern custom die casting
company saw substantial scrap reductions and quality improvements.
Top Die Casting had an opportunity for a contract to supply hydraulic adapters
for cherry pickers. The casting would require a 5000 PSI leak test after machining
and impregnation. The previous supplier had had scrap rates of up to 80%. To
avoid this, they decided to retrofit a 1978 650-ton B&T machine with Tymac's
SuperShot III.
Tymac's RTU-9000 analyzed filling conditions to develop an optimal shot profile.
In the first month of operation, a scrap rate of 8% was achieved. Over the next
two months, the RTU-9000 recommended further gating and process adjustments, and
scrap rates dropped to consistently below 0.4%. The customer was so pleased,
they dropped the leak test requirement, saving even more money.
As an additional benefit, Top Die Casting reports that they successfully do
800-ton jobs on their SuperShot-equipped 650-ton machines, due to the
effectiveness of the low-impact deceleration.