Practical PQ² techniques were developed in the 1970's to help die casters understand the relationship between a specific die-casting machine and die. Using a mathematical equation, PQ² graphically predicts metal flow. More specifically, it predicts metal velocity and cavity fill time with respect to the flow areas in the die.

If used properly, die casters can use PQ² to:

    Determine if a die casting machine and die are compatible for making quality parts.

    Design dies using the most effective flow areas.

    Problem solving for defects by determining gate velocities and cavity fill time.

The following program is a basic, easy-to-use form of PQ² get you started using the most powerful technique in existence for assessing how a die will perform on a particular die casting machine.

Process Sequence Analysis™ (PSA) is an effective method used to time the sequences of the die casting machine. The process can be timed by using a simple stopwatch and then graphed to compare the sequence of the machines. This program provides a format in which only the data needs to be input. The output is in the form of a Gantt chart, which can then be used to:

• Highlight individual sequences that can be shortened to reduce cycle-time and increase productivity.
• Enable accurate process costing.
• Highlight differences between die casting machines (making the same part).
• Create a more consistent process, resulting in consistent die temperatures, and consistent quality.

The cost of metal is of major importance to the die caster. It is, therefore, necessary to keep track of it at each stage of the process and in all its forms from the time it is purchased to the time the castings are dispatched. Stages such as melting, transporting, holding, casting, trimming and other post-trimming operations should be accounted for.

Forms in which metal exists include sows, ingots, molten metal, castings, dross, turnings, trimmings, floor sweepings, etc. Stages that should be accounted consist of melting, transporting, holding, casting, trimming, etc.

It is often convenient to account for each of these materials by its dollar value to permit a unified accounting procedure to be used that should also include the cost of metal recovery. The following spreadsheet is a generic accounting program that enables you to input either real of fictitious values to indicate where metal dollars can be saved, and how the overall cost of metal can be reduced