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LEAP – Diecasting Technology

World class diecasting technology solutions from YIZUMI.

The future looks bright

Aluminum and magnesium alloys offer considerable design benefits. With their advantageous weight-to-strength ratios and easy recyclability, these great materials contribute significantly to light-weighting efforts, especially in the automotive industry, worldwide. The diecasting process, offering competitive manufacturing cost and with a unique ability to integrate functions to reduce downstream cost, ensures attractive growth in our industry.

YIZUMI’s amazing success story over the last twenty years is a clear indication it is in an ideal position to take full advantage of the attractive growth in the diecasting sector in the foreseeable future. The company says: “Reflecting our confidence is our aggressive growth plan that includes our aim of becoming a Top three diecasting solution provider in the next few years.”

Successful diecasting operation

At YIZUMI, the last few years have been dedicated to developing state-of-the-art diecasting machines as well as developing great expertise and technical capabilities within the workforce. Both areas in which significant progress was achieved are indispensable to the company’s dedication to delivering the best cost effective solution with leading technology to customers worldwide.

The company says: “We understand that a meaningful manufacturing solution provides our customers with a competitive overall equipment effectiveness (OEE) at a very attractive total cost of ownership (TCO). In other words, an installed diecasting cell, offered at a fair price, first and foremost needs to allow its operator to enjoy a high equipment availability without the high cost of operating the equipment. The total cost of operation is heavily dependent on well trained personnel and on a suitable preventive and increasingly also predictive maintenance plan.”

To achieve a competitive OEE, only concentrating on the diecasting machine and the automation, however, would be very short-sighted. Successful and profitable diecasting production is only possible with a thermally balanced diecasting tool avoiding or at least minimising any cavity cooling requirements executed by external spraying. The highest levels of productivity can be reached if the casting part design is greatly optimised for the diecasting process in a way that tool aging effects are considered. This reduces die maintenance costs and allows the casting production to maintain a high OEE throughout the entire die life.

Supporting customers

The YIZUMI team is totally dedicated to providing the best effective solutions to the company’s customers worldwide. They understand that providing true value to customers entails delivering reliable and productive diecasting equipment. With the LEAP series of diecasting machines, YIZUMI offers a state-of-the-art system with a modern, easy to use control HMI, ensuring reliable casting production.

The real time closed loop injection control is based on a proprietary servo valve technology offering the highest flow rates and extraordinarily precise speed and pressure control. Negative casting process influences from possible temperature fluctuations of alloys or hydraulic oil, as well as varying friction forces within the shot sleeve, are quickly compensated and adjusted to the nominal settings. This allows the LEAP diecasting machine to maintain extremely high process stability and repeatability in any casting application.

The company’s ORCA control system, featuring high performance electronic hardware, offers a well conceived HMI providing an effective and transparent interaction with system operators and process engineers. A large programming screen with interactive, intuitive graphical displays and multi touch functions ensures high ease of use and effective programming with a minimum of training. A well structured menu allows the different system users such as operators, process engineers and quality managers, etc. easy access to their data and programming sections. Intricate ‘self-learning’ algorithms, which have been developed in house in collaboration with YIZUMI’s Sino-European Innovation network provide any LEAP production with outstanding precision and reproducibility – reliable quality shot by shot.

As YIZUMI is focused on sustainability, the company has developed various energy saving features for the LEAP series of diecasting machines. While an innovative two stage hydraulic drive unit saves up to forty per cent of electrical energy compared to conventional systems, it also substantially extends the service life of the pump by a much optimised ‘feeding oil management’. Differential hydraulics in the pre-filling phase of the injection reduces overall electrical energy usage by a further twenty per cent. The company says: “The LEAP diecasting machine is without a doubt a highly competitive product aimed at providing substantial benefits to our customers. 

“Above all, YIZUMI’s support of our customers includes all relevant service support efforts. Our competent aftersales service team, in combination with an efficient worldwide spare parts service, ensures that our customers achieve high equipment availability.

“We educate more than five hundred trainees in relevant topics yearly at YIZUMI training facilities as well as at customer plants worldwide.

“We round off our customer service capabilities with expertise drawn from our international network in the areas of tooling design, along with casting process simulations which include excellent interpretation and accurate conclusions of said simulations.

“High quality casting cell solutions with high performance enhanced with our YIZUMI customer service packages provide our customers with effective best cost solutions.”

Value adding applications

The company claims: “YIZUMI’s LEAP series of diecasting machines are an asset for any diecasting operation, adding value by providing an extraordinary casting performance.” However, especially in the field of thin walled large surfaced diecasting components like structural castings, the LEAP technology proves especially beneficial with its high performing injection capacity (P/Q2) paired with its “unmatched precision” and process repeatability. The highest injection speeds ensure the short filling times needed for such parts, while a highly precise braking of the injection speed reduces flash and protects the tooling. Since the LEAP series of machines is available in all machine sizes up to 90,000kN of locking force, this machine technology is perfectly suited to produce ultra large casting applications.

Continuously adding value for customers

YIZUMI is a reliable partner dedicated to providing cost effective diecasting solutions to customers worldwide. The company says it will continue to leverage its local resources and its network of international experts to build up relevant know how to contribute to the company’s client’s competitiveness.

Contact: YIZUMI Holdings Co Ltd,

LEAP Series diecasting machine