Archive for August 2010

Aug 26

Five Characteristics of Good Managers

1) They are genuine. They are warm and engaging not only about themselves, but also their businesses. They are forthright about their strengths and weaknesses. They admit that they do not know everything, and seek advice from others. Their authenticity is apparent.  They tell the truth and are transparent. 2) They are comfortable with uncertainty. They know that what worked yesterday won't necessarily work tomorrow. They optimistically view uncertainty as fuelling the fires of creativity. They turn anxiety that accompanies change into productive energy for moving forward. They impatiently push people to stretch while creating a supportive work environment. They exude confidence while remaining humble. 3) They see people as the primary driver of the firm's success. They believe in investing in people first. 4) They focus on the future, challenging the company to grow faster, and encourage others to experiment and take bold steps. 5) They have a passionate desire to succeed, constantly raising the bar. They ensure a sense of accountability in the organization. They push decision-making and authority down in an empowered, accountable organization that they foster.
Posted by: probbins
Aug 24

Heating the Extrusion Die...Opportunity Beckons (3)

RDX (Robotic Die Expediter) Even the best single cell die oven cannot guarantee that the die will be uniformly at billet temperature for the first billet in every run, or that “best practices” will be followed.  For this reason, Castool recently introduced the RDX.  The RDX expedites the scheduling and heating of the die from the time of its arrival from the die shop until it is installed on the press. Although the die will be heated and moved according to a prepared formula, the press operator will continue to have complete control at all times, and will make all necessary decisions during every step in the process. The Future The technology of light metal extrusion has improved considerably in the past few years.  Even the best extruders, however, are not yet able to make best use of the technology now available.  The reason for this is that the variety of leaner alloys now being made to provide strength, physical properties and surface finish as well as increased ram speed does not nearly match the variety that would benefit extruders whose improved temperature measurement and control would now make their use possible.  In the future, the extruder will have a broad spectrum of designer alloys to choose from.  He can then take full advantage of the fact that he has very close control of the alloy temperature from the time the billet is heated until the alloy exits the die in the desired profile.
Posted by: probbins
Aug 19

Heating the Extrusion Die...Opportunity Beckons (2)

The Single Cell Die Oven The single cell die oven using radiant energy, is now accepted globally as the premium contemporary technology for safely, accurately, and rapidly heating extrusion dies. A good single cell oven must bring the die to a uniform target temperature in a relatively brief period of time, without exceeding the annealing temperature of the Hi13 die steel, or negatively affecting the nitride layer, while using as little energy as possible, and having a small footprint, Challenges If a die is left at temperature for a lengthy period, the bearing will oxidize.  This will result in poor surface finish on the section. If the correct heating cycle which included a “heat-head” for the die is not used, the oven will act as a soaking oven, extending time to temperature and/or delivering cold dies to the press. If more than one die is put in a single cell oven, all temperature control is lost. The single cell oven then becomes simply a small chest oven. If a die sits for a prolonged period before being run, all accuracy is lost.  Unless controlled, a heated die in shop floor ambient temperature will lose 50C every 10 minutes.  In addition breakthrough pressure will be considerably increased. CASTOOL Tooling Systems Castool pioneered the use of single cell die ovens after they first appeared in Japan in the early 80’s, and just now has well over 1000 ovens in use globally.  Current models reflect the experience gained over the years as the technology of die heating has gradually evolved. One key to the most effective use of single cell ovens is the optimizing of the heating program used for each die. It is based on the size and mass of the die, thermo-conductivity of the die steel, energy added by the resistance heaters, and heat lost to the environment. From the mass of knowledge now available to Castool from its large user base, the logarithm used on its controller for each die is now in fact a calculation rather than an estimate.  This method is the most reliable means today to accurately and safely heat a die. Castool is well-known for the ongoing service and technical advice it provides its customers.  This is usually expedited by its large network of local representatives. Typically, a new die oven customer will provide Castool with a die that will then have several thermocouples installed.  Its heating cycle will then be fully documented prior to delivery, or at the customer’s plant after delivery.  Existing single cell die ovens can also be documented for temperature and energy use
Posted by: probbins
Aug 18

Billet Lubricator/Quench

billetspray Press for link: Movie Billet Lubricator/Quench Extruders apply boron nitride traditionally with a dry powder electrostatic application, using the release agent characteristics of boron nitride to avoid dummy block surfaces sticking to the rear face of the billet to ensure any extrusion butt stays attached to the die prior to shearing.  Use of boron nitride is successful in that it satisfies the objective of acting as an effective release agent.  However, difficulties in maintaining a full electrostatic charge often results in the need for over application with resulting powder overspray losses and housekeeping issues around both the boron nitride applicator and billet loading equipment. Castool Tooling Systems has developed a unique process of application of liquid boron nitride to a preheated extrusion billet prior to loading into the press. The process enables improved coverage compared to boron nitride powder application with much less overspray and lower consumable costs, with the additional benefit of cooling the rear of the billet prior to extrusion, thus enabling higher extrusion speeds. The process applies liquid boron nitride solution using high pressure low volume atomization nozzle technology.  High pressure atomized spray is capable of penetrating the thermal barrier (insulating steam layer) normally generated during most water spray quenching processes.  Penetration of the thermal barrier, which has been an obstacle to successful liquid application in the past, is now possible.  The use of high pressure atomization therefore allows more effective adhesion of boron nitride and improved efficiency of boron nitride application = lower consumable costs. It is well recognized that taper preheating of billet is an effective means toward high productivity isothermal extrusion.  During transfer of a billet from billet oven to press, there is opportunity to hold the billet at the liquid boron nitride station, and prior to application of a boron nitride solution the rear face of the billet can be sprayed with atomized water for up to 20 secs (or longer if the extrude cycle allows).  Low volume high pressure application of a fine droplet spray ensures most of the water is evaporated, resulting in high heat transfer from the billet.   Modeling predicts that 20 seconds spray can create a 35oC (63oF) taper difference in billet temperature front to back end immediately prior to loading the billet into the container.  Trials have demonstrated that this level of taper can result in a 15% extrusion speed improvement.   After spraying with water for a predetermined interval to cool the billet rear face, the unit then efficiently sprays with a boron nitride solution.  While atomization is designed to ensure close to 100% vaporization, any excess water or solution that may result can readily be captured and recycled for re-use. Efficient application of a boron nitride liquid boron nitride solution using the  Castool spray atomization method offers benefits of not only reducing boron nitride costs, improving adhesion of boron nitride to the preheated billet surface, but more so is capable of significantly increasing extrusion speed and productivity by cooling the rear end of the billet.  Payback can be close to immediate!
Posted by: probbins
Tags: 
extrusion equipment
Aug 17

Heating the Extrusion Die...Opportunity Beckons (1)

The Opportunity

Most extruders today are not yet using single cell die ovens, despite their obvious advantages.  If an extruder has made a satisfactory profit for many years while using a chest oven, it is naturally hard for him to become persuaded that he will benefit by the installation of several single cell die ovens.  But these are no longer normal times.  In today’s unique economy, it is unlikely that any extruder can afford to waste the first one or two billets at the start of every run in order to bring his die completely and uniformly   to operating temperature. For the extruder who saves the cost of a wasted billet on every run, coupled with his saving in energy costs, the return on his investment can be attractively short.  Castool has assisted a number of extruders in obtaining government grants for energy conservation. The Process Extruding aluminum appears to be a simple process.  It is not.  A billet of an aluminum alloy is heated until it is soft, then it is pushed through a die which determines the resulting profile.  In this very brief moment of extrusion, as the alloy passes through the die, it hardens, the profile is set, and most of the added value on which the extruder depends is generated. If the die is well designed and well made, the shape that leaves it should meet all dimensional tolerances, have a good surface finish, and be moving at a profitable speed from the first billet to the last.  This can only happen, however, if three specific conditions are satisfied.  First, the alloy must enter the die at or near its optimum operating temperature.  Second, the die must be completely and uniformly at the optimum operating temperature of the alloy being used.  Third, the temperature of the die and the exit temperature of the extrusion should remain virtually unchanged from the beginning to the end of each extrusion cycle. Varying the ram speed should not be an option because the dimensional integrity of the profile may then be compromised.
Posted by: probbins
Aug 12

There is no such thing as a stupid question

People can be more successful by asking genuine questions designed to elicit information. There are 4 styles that can be used depending on the situation. Professor: You use this when needing to better understand a situation, when exploring new ideas, or when trying to identify all potential factors affecting a situation. Questions: What's the goal? What are you options? What are the alternative choices being considered? What is the current reality? What other approaches have you tried? Judge: You use this when you are seeking knowledge and attempting to evaluate as you analyze options. Questions: Whose decision is it? What is the most important consideration? Which option makes the most sense to you? What are the consequences of the choices? What conclusions have you reached so far? Are the risks for each alternative manageable? What is the greatest possible success? Innovator: You use this when trying to gain a perspective on the future. These questions maybe asked to explore new directions, identify opportunities, improve current methods, or develop innovative solutions. Questions: What would do if the funds were unlimited? What is your recommended way forward? Is there anything I can do, add, or absolve you of that will make this easier for you to decide? What does your gut tell you to do? What will the end result be? Director: You use this when evaluating how best to proceed and take action. Questions: When is a decision due? Is this close to a 50-50 decision, and if so should we flip a coin? What needs to happen for that to succeed? Do you feel that you have my support? If you make the wrong decision, is it reversible?
Posted by: probbins
Aug 10

Thought-provoking Marketing

The best marketers today use campaigns that add value to their consumers. They tap into emotional connections, enhance customer experience, and are thought-provoking. Many marketers persist in selling on logic rather than emotion, because it is rational, easier and safer. Emotional selling is tougher, mainly because it does not work unless it is authentic. People really do want a reason to love your brand. A lot of brand communication is driven by what is the best thing we can say about our brand, instead of what is it that consumers really need? Creative marketing means thinking laterally. It is about making unexpected connections that look and feel completely natural. The best marketing today focuses on the role of brands in consumers' lives.
Posted by: probbins
Aug 6

The human factor must always be considered

RDX2 With a base of more than 1000 single cell die ovens just now being used globally, Castool’s source of current knowledge of the extrusion process is unmatched.  Even the best single cell die oven is no guarantee that the die will be precisely at billet temperature for the first billet in every run. The human factor must always be considered.  Castool’s Robotic Die Expediter reduces the human factor by automatically moving and heating the die according to a prepared formula, from the time it arrives until it is placed on the die slide by the operator. Please visit the RDX video at www.castool.com/products/extrusion/RDX
Posted by: probbins
Aug 5

For Better Die Casting

The market for light metal die-castings continues to grow.  Castings are becoming bigger, more complex, and better in every way.  Technology is keeping pace with the changing market, but castings are still made by die casters, not just by machines, and the die caster’s basic approach to the production process is just now more important than ever. For better die casting, the effectiveness of interacting components should never be considered individually, but always together.  Die-casting is, in fact, a process that can only improve when all parts work together as a system. The most obvious interaction is between the plunger and the shot sleeve, but vacuum is becoming increasingly essential, and it requires an effective plunger-shot sleeve function.  All three components are therefore connected, and form part of the overall system. Experience has proved that always considering the casting process to be a unified system rather than merely a group of disparate components virtually assures increased productivity.
Posted by: probbins
Aug 3

Porosity and Vacuum

  In cold chamber die casting of light metals, because of the turbulence of the alloy as it is forced at a high pressure into the die cavity, and the complex shape of many casting molds, air and other gases are often trapped in the metal.  This, of course, results in porosity in some parts of the casting. If the casting is to be chromed, painted, or powder coated, or if any part of the casting is very thin, any air or gas inclusions usually result in rejection.   Porosity also affects the mechanical properties of the product.  In structural applications, porosity can act as a stress concentrator and therefore create a site where cracks may occur. An additional problem is the fact that porosity in a casting may not always be immediately apparent. If discovered after subsequent processing, customer dissatisfaction can be extreme. Porosity in the casting can be almost completely eliminated by an efficient vacuum system. Before the injection shot occurs, a vacuum is drawn in both the shot sleeve and the mold cavity.  The vacuum is maintained until the injection cycle is completed.  Almost all of the air is positively evacuated from the mold. A good vacuum in the mold cavity enables the alloy to flow into blind recesses in complex shapes.  It also allows the fronts of the molten metal to merge freely without forming shuts. Whatever vacuum method is employed, if it works well, improved quality and reduced scrap can be guaranteed. The principal benefit of vacuum is to eliminate porosity.   Product that is rejected is unusually costly to the die caster.  For example, the value of the machine time that is lost while producing the rejected product can never be   recovered. Adding a vacuum system to the operating process benefits a die caster in several   ways.  First, it reduces his rate of rejection.  Second, by lessening the force required on the plunger, it increases the life of almost all components of the DCM.  But most importantly today, by allowing the die caster to produce thinner, stronger, and more complex castings, it makes it possible for him participate in a fast growing market sector to which he would otherwise be denied.
Posted by: probbins

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