Cavitation reduction is not as simple as blocking off a couple cavities and continuing to run. The process should be as close as possible to the original process, but this will require an adjustment to the process inputs.
Do you have a good process for blocking cavities?
The process is almost identical to the original, but these are some of the characteristics of the new process:
Process Inputs/Outputs which should not change from the Standard Process:
- 2nd Stage Packing Time
- 2nd Stage Packing Pressure
- Cooling Time
- Back Pressure
Process Outputs which should not change from the Standard Process (may require a change to the process inputs):
- 1st Stage Injection Time
- Recovery Time
- Coolant Temperature
- Cycle Time
Process Outputs which will change from the Standard Process (may require a change to the process inputs):
- 1st Stage Injection Weight = (Standard 1st Stage Weight)*(New Cavitation)/(Standard Cavitation)
- 2nd Stage Final Part Weight = (Standard 2nd Stage Weight)*(New Cavitation)/(Standard Cavitation)
- Clamp Tonnage = (minimum tonnage required)*(1.1)
Cavitation reduction should always be avoided or remedied whenever possible. Since the cycle time does not change, a 25% reduction in cavitation requires 33% more cycles to produce the same number of parts. Such a process is always less stable than full cavitation, so the defect rate will also increase with reduced cavitation. This can quickly reduce overall production capacity and often make the difference between profit and loss.