Analysis and optimization of zinc alloys die casting process
Eleonora Tibaldi
Analysis and optimization of zinc alloys die casting process.
Rel. Graziano Ubertalli. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Meccanica (Mechanical Engineering), 2021
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Abstract
Process optimization to improve quality of parts, to enhance production times and, consequently, to reduce costs, is a crucial element in manufacturing companies. The aim of this Thesis, result of my five months internship at the Quality department of Dynacast Italia Torino S.p.A. in Grosso (TO), is to introduce efficient improvement actions to the current hot chamber die casting process of zinc components. For this purpose, it is first necessary to provide a general introduction to zamak alloys, offering an overview of their composition, mechanical properties and influence of alloying elements, outlining also the basic functioning principles of hot chamber die casting machines which, combined with the versatility of zinc alloys, allow the reaching of high quality performances within advantageous times and costs.
After a detailed casting defects analysis, considering all the possible formation causes and potential negative effects on the final product (reduced strength, aesthetic or functional problems), researches performed in Dynacast, during the internship experience, have demonstrated that continuous quality improvement studies are necessary to define efficient action plans to prevent defects occurrence; for this scope, the thesis work reports practical implemented corrections resulted in tangible quality benefits, reducing waste during production and ensuring saving costs
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