Analysis and optimization of a die casting process by means of a simulation system

This work is about the analysis and the optimization of an automatic and modular die-casting plant for aluminium domestic radiators by means of a simulation software. Objectives of the work were the analysis of the more important variables of the process and the evaluation of the best configuration. A reconfigurable model of the whole plant was set up using the commercial code Arena 7.01 (Rockwell Software). The as-is configuration was studied and some possible to-be configurations were taken into account. Once the model was created, an accurate validation was executed comparing results obtained by simulations with data collected from the company’s production database. A statistical approach was adopted to reduce the average differences between experimental and numerical results, in terms of produced items. Several tests were finally performed for the process optimization by testing the effects on the production rate of process parameters modifications and new devices implementation