FAR Uses Two Cavity Die to Improve Production Rate and Margins
CastingHeavy Industry & Machinery 
Today, Casting simulation is mandatory and necessary to reach the best quality results, including choosing the right tonnage of the machine to reduce costs. With these results in quality and costs, FAR can be competitive on the market.
Challenge
In order to increase production of an automotive oil pump, FAR knew they needed to move from a single cavity die to a double cavity die. With this change, they would need to keep costs low yet still produce the highest quality casting possible. Therefore, it was important to determine the best die casting machine (DCM).
Story
FAR was producing an automotive oil pump successfully on a single cavity die using a Colosio 560 tons DCM. An increase in production was required and the obvious thought was to move to a double cavity die. Emperical calculations suggested using a 1200 ton machine. Ecotre, ESI & Colosio teamed up to increase the high fidelity level of ESI ProCAST by integrating simulation & die casting machine. This allowed them to select the right size machine and lower production costs. This innovation, together with a Fondarex vacuum system, was virtually simulated in ESI ProCAST to produce the highest quality casting. Simulation suggested to opt for a 750 ton machine rather than 1200 tons, as proposed by emperical calculations.
Benefits
This new ESI ProCAST functionality allows simulation to account for DCM characteristics. FAR successfuly switched from one to two high quality cavities and engineered a new die design for the right die casting machine at a minimum cost.
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