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Optimizing Die-Casting Simulation and Design in Automotive Industry: A Case Study of U-Shin Automotive
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Automotive
- Equipment & Machinery
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Manufacturing Process Simulation
- Virtual Reality
Services
- Testing & Certification
The Challenge
U-Shin, a global automotive parts manufacturer, faced a challenge in die-casting simulation, result analysis, and design optimization for an automotive dead lock pin. The company specializes in automotive system appliances and mechatronics, producing a wide range of products including lock sets, electronic steering column locks, climate control panels, door latches, keyless entry, door handles, switches, power closure systems, and rear access modules. Many of these parts are manufactured with zamak, a zinc-based alloy. U-Shin's zamak foundry, one of the largest in Europe, produces approximately 10 tons of zamak per day. The company faced the challenge of optimizing over 100 tools per year, a process that is crucial for reducing time and cost, and for providing reliable solutions to customers in the automotive industry.
About The Customer
U-Shin is a global automotive parts manufacturer, specializing in automotive system appliances and mechatronics. The company's main product line includes lock sets, electronic steering column locks, climate control panels, door latches, keyless entry, door handles, switches, power closure systems, and rear access modules. U-Shin's expertise ranges from mechanical machinery design to electronic engineering and software, offering full support from development and design of various parts and systems to manufacturing. The company takes pride in being a worldwide leader in performing high pressure die-casting with zamak, a zinc-based alloy. U-Shin's zamak foundry is one of the largest in Europe, producing approximately 10 tons of zamak per day.
The Solution
To address this challenge, U-Shin employed solidThinking Click2Cast to perform testing and optimization. This software allowed U-Shin to simulate, observe, and gain better insight into the flow and material characteristics of zamak, which is crucial for producing quality and reliable parts. The extensive material database that Click2Cast offers enabled U-Shin to simulate the casting process for various parts under a variety of stresses. One of U-Shin’s projects involved analyzing the failure of an automotive dead lock pin and redesigning the part based on the simulation results in Click2Cast. The point of failure in the dead lock pin occurred during the vibration test. U-Shin continues to use Click2Cast on several automotive projects, allowing the company to better anticipate, modify, and improve designs.
Operational Impact
Quantitative Benefit
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