Development of the DFMEA method for high pressure die-casting mold design and manufacturing

V nalogi je predstavljeno načrtovanje metode DFMEA za razvoj, snovanje in izdelavo visokotlačnega livarskega orodja za litje aluminijskih izdelkov za avtomobilsko industrijo. Uvodnemu poglavju, v katerem so definirani obravnavana problematika in cilji naloge, sledi poglavje, v katerem podrobneje predstavljena konstrukcija in delovanje visokotlačnega livarskega orodja, pojasnjeno pa je tudi delovanje vseh sistemov, ki so del orodja in omogočajo kakovostno litje. Nadalje je v nalogi predstavljen celoten proces razvoja, snovanja in izdelave livarskega orodja v orodjarni. V metodološkem delu magistrske naloge je predstavljena metoda FMEA, z uporabo katere smo načrtovali DFMEA livarskega orodja, ki vsebuje smernice za izdelavo optimalnega in robustnega dizajna livarskega orodja za preprečevanja pojava napak in doseganja pričakovanih funkcij. V četrtem poglavju magistrske naloge so po korakih predstavljena izvedba in rezultati uporabljene metodologije DFMEA na primeru visokotlačnega livarskega orodja. Z uporabo zasnovane metode DFMEA bomo lahko med izvajanjem posameznega projekta identificirali in ovrednotili specifična šibka področja dizajna in konstrukcije novih ali obstoječih livarskih orodij. Tem bomo lahko s pomočjo naučenih lekcij in reklamacijskih zapisnikov optimizirali dizajn, kar neposredno vpliva na boljšo kakovost ulitkov in zanesljivost livarskega orodja.This thesis presents the development of the DFMEA method for the R&D, design, and manufacturing of high-pressure casting molds for aluminum products for the automotive industry. The introduction chapter, which defines the discussed issue and objectives of the thesis, is followed by a detailed presentation of the mold construction and its operation and also explains the operation of all systems that are a part of the tool and that enable high-quality casting. Furthermore, the thesis presents the entire process of development, design, and manufacturing of the die-casting mold in the tool shop. The methodological part of the thesis presents the FMEA method, which we used to develop the DFMEA for the die-casting mold and that contains guidelines for designing an optimal and robust mold design to prevent the occurrence of failures and achieve the mold’s primary functions. The fourth chapter of the thesis presents step-by-step the implementation and results of the DFMEA methodology used for the high-pressure die-casting mold. Using the DFMEA method, we will be able to identify and evaluate specific weak areas of the design and construction of new or existing molds for each project. With the help of the lessons learned and reclamation reports, we will be able to optimize the mold design, which directly affects the casting quality and the reliability of the molds