Cut Operating Costs by using Rheocasting

The current times are harsh. Energy costs and interest rates are rising drastically. At the same time, margins for new castings are decreasing. So, operating costs are a key figure to watch to survive.

The operating costs of a diecasting machine are determined by initial investment and the resulting depreciation. So, casting on older fully depreciated machines or smaller machines is a cost-saving measure. In addition, energy costs and spare parts must be factored into the calculation. The same principle applies here: Smaller machines are cheaper. They consume less energy and have smaller, therefore cheaper spare parts.

But how can you reduce the machine size with Rheocasting and cut those costs down?

Let’s dive into how the machine size is calculated. The clamping force is mathematically the projected area multiplied by the maximum pressure. But not all the projected area counts. Only the areas where it is still liquid count towards the calculation of the clamping force. Here comes the “pocket warmer effect” into play. You have a better and longer filling. So, the still liquid area is in Rheocasting larger than in HPDC. However, for the part design in Rheocasting, the projected area can be reduced to 50% of the HPDC version. Also, a smaller tool saves a significant amount of money.

Still, the Rheocasting part is not cast on half the machine size. Several specifications of the machine have to be considered. Smaller machines with large (for that machine size) plungers have a lower pressure. Rheocasting parts can have lower pressures in the third phase, still they need for a certain metal pressure.

Another point is the distance between the DCM columns. The part with the robot grabber has to pass through that width.

A last point I want to make in this article is the capacity of your production. For example, if you could mathematically cast it on a 1400-ton machine but there is no capacity, then you must take the next larger machine that is available for production.

When you sum up all these factors, you usually end up with a 30-40% smaller die-casting machine in Rheocasting than in conventional HPDC. This not only saves you a lot on operating costs, but it also reduces the consumed energy and the resulting carbon footprint.

When you want to cut your operating costs with Rheocasting or your existing HPDC foundry, look closely at the Process Optimization Workshop. It is designed to find inefficiencies within your foundry. Schedule a free consultation below to reduce your operating costs.