3x longer plunger lifetime with Performa Plunger

INTRODUCTION

This case study explores the benefits of the Performa Plunger, focusing on its longevity, cooling efficiency, and impact on cycle time.

The study aims to evaluate the performance of the Performa Plunger compared to traditional Beryllium-Copper (BeCu) plungers, with focus on lifespan, cooling efficiency, and overall impact on production efficiency.

backround

Our customer, located in Europe, was using traditional BeCu plungers and was dealing with challenges such as frequent plunger replacement because of its limited lifespan. 
They were looking for a solution that provided both good cooling and extended service life to enhance overall productivity.

Methodology

The Performa Plunger, integrated with the iTherm® cooling system, was installed in one of their machines. Performance data were collected over several production cycles, comparing the results with those of traditional BeCu plungers.

Metrics

- Plunger lifespan (number of shots)

- Cooling efficiency (heat removal rate)

- Cycle time reduction

- Component wear and maintenance requirements

Findings

Plunger Longevity Comparison

An average-sized BeCu plunger (~100mm in diameter) typically lasts 4,000-7,000 shots.
In contrast, a Performa Plunger of the same size can last 50,000-80,000 shots, with each ring lasting 20,000-30,000 shots. 
Notably, a Performa Plunger remained operational after 91,000 shots and three ring changes (every 30,000 shots).

Cooling Efficiency and Cycle Time Reduction

Steel tips are known for their longer lifespan compared to BeCu tips, but BeCu is often used to enhance cooling near the biscuit. 
The Performa Plunger's conformal cooling surpasses the heat removal rate of BeCu tips, offering a solution that maximizes both component lifespan and cooling power.

Die casters using the Performa Plunger have reported a 7-15% reduction in cycle time in systems limited by biscuit cooling.
Further cycle time reductions can be achieved by implementing conformal cooling on shot blocks and die cores or cavities.

Conslusion

The Performa Plunger, with its advanced internal cooling system, significantly outperforms traditional BeCu plungers in terms of lifespan and cooling efficiency.

By reducing cycle time and maintenance requirements, it offers a compelling solution for die casters seeking to enhance productivity and lower operational costs.

For more detailed insights and personalized consultation on how the Performa Plunger can benefit your operations, please contact us.