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The redesigned one-piece magnesium enclosure (right) houses vital components in its application within the projector (left).


impact any mating parts,” said Adele Evans, director of global supply chain management. Te design for the problematic casting was sent to one of


Christie’s existing casting suppliers for quotation purposes. During a phone call after receipt of the drawings, engineers discussed some technical issues for the enclosure, which had been a two-piece casting produced via thixomolding, a process of injection molding of a semi-solid alloy. In explor- ing possible solutions, the two sides pursued a concept of the housing that would turn the component into a single magnesium die casting. Within a few months, collaborative technical discus-


sions and flow analyses were taking place for the one-piece design. Reducing the component to a single casting would reduce part count ratio, improve physical and mechanical properties, simplify inventory management and minimize required machining. “With the original design, not only did you have a


two-piece assembly, which is more expensive, but you also had the assembly component to it,” said Eric Voss, Chris- tie advanced product developer. Te two-piece assembly also could “result in potential final assembly issues on the production line.” By simplifying the assembly into a single diecast compo-


nent, Christie and its supplier decreased shipping, tooling and machining costs while improving the casting design. Te developments also improved dimensional accuracy and cut the component’s weight 8%.


Seeking Out Suppliers Through past experience and education, Christie’s


engineering department includes experts with casting experience to help identify potential candidates for the manufacturing method. Once a part is identified as a potential casting (or a redesigned casting), Christie’s pur- chasing department tries to identify metalcasting facili- ties from its current qualified supplier list. If one cannot


重新设计的一体式镁合金外壳(右)用于投影装置( 左)内,容纳重要的零部件。


“该项目有几个简单的目标:识别并减少设计的约束 条件和实际生产过程的成本控制,同时确保这些变化不 会影响任何配套的零件,”全球供应链管理总监阿黛尔• 埃文斯说。


有问题铸件的设计图被送到正在给Christie公司供货 的一家铸造厂作报价。在接收到图纸后的通话中,工程 师们讨论了外壳铸件的一些技术问题,该两件一套的铸 件一直经由两种铸造工艺生产,触变成型和合金半固态 注射成型。在探索可能性的解决方案时,双方提出设想 将外壳铸件改为采用镁合金压铸工艺的单一铸件。 在短短几个月内,通过协同技术讨论和信息流分析法 实现了铸件的一体式设计。将该部件改为单体铸件可以 减少零件总数量,同时改善物理和力学性能,简化库存 管理,并尽量减少所需的机械加工。


“用原来的设计,不但是由两个零件组装,成本较 高,而且还需要装配零件的工具,”Christie高级产品开 发经理埃里克•沃斯说。该两件式的零件也有可能“导致 生产线最终装配时出现问题。”


通过简化成单一的压铸件,在改进铸件设计的同 时,Christie和供应商减少了运输,模具和加工的成本。 这款新产品也提高了尺寸精度并减少了零件8%的重量。


寻找供应商


根据以往的经验和培训,Christie的工程部门,包括 有铸造经验专家,可以帮助识别潜在的候选制造工艺。 一旦零件被确定可用潜在替代工艺铸造(或铸件被重 新设计),Christie的采购部门会设法从当前合格供应


56 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION June 2015


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