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Die Casting News

Engineering Die Casting Dies: Dimensional Repeatability - NADCA Video Highlight

Posted by Hill and Griffith Company on Jan 2, 2019 10:09:26 PM

Define what the customer wants and use a standard approach to what the die casting process can achieve.

The material presented in this video are some highlights from NADCA’s online webinar – Engineering Die Casting Dies: Dimensional Repeatability. This looks at defining what the customer wants and gives a standard approach to what the process can normally achieve, with such things as dimensional tolerances and flatness. It covers defining what your plant can achieve on a day-by-day basis using a small amount of math.

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Tags: Die Casting, Die Casting Process Improvement, Die Casting Process Evaluation, Die Casting Process Modeling, Die Casting Process, NADCA Video Highlight, Die Casting Surface Defects

Die Casting Surface Defects Caused by Die Temperature

Posted by Hill and Griffith Company on Dec 28, 2018 5:16:08 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

The die temperature’s effect on surface defects and the die temperature operating window will be discussed next

  • A low die temperature affects surface defects by cooling the fluid metal stream and increasing the percent of solidified metal in the metal stream
  • If the percent of solidified metal is high, then it becomes stiff and solid and does not knit together well; And the flow forms "wrinkles", or cold flow
  • A cold die can be compensated for by having a shorter fill time - this means a higher plunger speed
  • In other words, we can exchange plunger speed for die temperature.
  • Measuring die temperature should be done on every job - most don’t do it enough, but it is required to really minimize surface defects
  • In general, measuring can be done three ways: – Hand held probe – Thermocouple in the die – Infra red device
  • Each has advantages and disadvantages: Hand held probe: accurate, but must stop the machine; Thermocouple in die: continuous, but does not measure surface temperature; Infra red: easy, but not as accurate
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Tags: Die Casting, Die Casting Process Improvement, Die Casting Process Evaluation, Die Casting Process Modeling, Die Casting Process, Die Casting Surface Defects

Happy Holidays

Posted by Hill and Griffith Company on Dec 19, 2018 2:24:20 PM

Season's Greetings from our family to yours.  

Hill and Griffith's Management & Sales Team 

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Tags: Die Casting, Die Casting Process Improvement, Die Casting Process Evaluation, Die Casting Process Modeling, Die Casting Process, NADCA Video Highlight, Happy Holidays

NADCA Video News Update, "Thermal Design - Why Bother?"

Posted by Hill and Griffith Company on Dec 12, 2018 11:21:26 AM

Why thermal design is important.

 

The material presented in this video are some highlights from NADCA’s online webinar - Engineering Dies: Thermal Design - Why Bother. This covers WHY the thermal design is important. It introduces the simple, but important variables such as surface area and the amount of heat that needs to be controlled. It has been clearly shown that using excess die spray to control die temperature usually results in lower die life, higher variation in quality day-to-day and increases gas porosity. Thermal design is important but can be simple.

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Tags: Die Casting, Die Casting Process Improvement, Die Casting Process Evaluation, Die Casting Process Modeling, Die Casting Process, NADCA Video Highlight

Get a Handle on Die Casting Defects with NADCA

Posted by Hill and Griffith Company on Oct 31, 2018 9:49:40 AM

This series of courses is devoted to understanding and identifying the probable causes of defects in die castings.

And to determining and implementing solutions that minimize or eliminate the effects of the problem. Learn more at the North American Die Casting Association site.

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Tags: Die Casting, Die Casting Process Improvement, Die Casting Process Evaluation, Die Casting Process Modeling, Die Casting Process

Video News Update: NADCA Die Casting Product Specification Standards

Posted by Hill and Griffith Company on Oct 24, 2018 10:42:06 AM

Tooling information, alloy properties, tolerances, GD&T, design guidelines, quality assurance provisions and more.

 

The material presented in this video is intended as an update on features in NADCA's Product Specification Standards manual - PUB-402. This manual covers specification, design and production guidance for both users and manufacturers of conventional high pressure die castings.

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Tags: Die Casting, Die Casting Process Improvement, Die Casting Process Evaluation, Die Casting Process Modeling, Die Casting Process

NADCA Video News Update: Die Casting Process Modeling

Posted by Hill and Griffith Company on Nov 22, 2017 12:10:22 PM

The material presented in this video are some highlights from NADCA’s online webinar - Modeling: Die Casting Modeling Capabilities - presented by Charlie Monroe.

From the November 22, 2017 Newsletter

In this course capabilities of die casting process modeling will be reviewed from the current NADCA literature. Common modeling approaches and typical results will be discussed. Topics include: What is simulation, the hows of simulation, and more.

Click here for information.

For information on purchasing a downloadable copy of this webinar in its entirety, please visit: www.diecasting.org/store/detail.aspx?id=WEB072

From the highlight:

 "Once you have a project description and a clear objective for that simulation, the next question is always how detailed do I need to get on those geometries that I need to simulate. The statement at the top basically is saying without the "right" geometry, as produced on the shop floor, you can't expect to get comparable results

I have, let's say, an expected geometry on the top line, and then I have three different options for simulation on the bottom. Everyone may laugh and say the geometry representation on the left is not very good, but if all I'm interested in the solidification time, for instance, perhaps that core doesn't really, or that slide doesn't really take up much of the solidification heat, and so my simplified block is sufficient to give me the overall solidification time, so I know how long the duration is. That would be one option.

Then in the middle section, you can see that I've removed all the draft, and I have included a slide in this case. In that case, maybe the draft didn't influence my results. If I'm not interested in the filling, if I'm only interested in where is the hot spot in this part, that geometry in the center may be sufficient to answer the question.

Then, on the right, I have probably the most faithful representation of that geometry, but again, maybe I'm missing the parting line, or this may give me more inclination about what the fill might be, what is the finished section on the part, but it still might be missing some different pieces. Again, even from this perspective, you can see that with particular forms of the geometry, I can answer questions, but certainly, if I had a question of whether the draft is sufficient, the two cases on the left is not going to be able to answer those problems for me. I have to make sure that I've included the right pieces of the geometry, the drafting, the correct holes if those are actually cast in holes or removed. Those are all questions that need to be answered as you're going through your model.
This is just giving some additional examples of things that could happen. I certainly ran across many of these when I was working with Caterpillar.



When we're asked to, for instance, quote a geometry or think about it, knowing which of those features are the machined features and what additional stock might need to be added if it is a machined feature may be a missing part of the geometry. Certainly, missing features or unanticipated features that are in there can be a problem for getting a realistic answer to the simulation.

The incorrect runner system from what happens on the die versus what happens in our 3D modeling is a problem.

Any lack of venting or thermal lines are all examples of ways we need to reconcile our geometries with the simulation.

In the process of talking to at least one simulation company about their service group, and when you contract service with them, what was the biggest problem that they saw with the simulations and the setups that they were getting, they quoted a number that was fairly high, that it was about 80% of all the problems with non-comparable to simulation results came from the wrong geometry or the wrong mesh that they had.

Again, these are not problems generally. I know I never go into a project where I'm intentionally trying to not simulate the right geometry, but then in the process of ... Normally our simulations are run earlier, and then later we go back, and we have an actual process, going back and validating that what happens in the shop practice versus what happens in our simulation world, it's very important to reconcile so that we can diagnose future problems that we'd end up having.

To purchase access to this course, visit the NADCA Marketplace at www.diecasting.org/store. Purchasing a course through the online education system grants you one year of access to the recording, presentation, support material, and test when applicable.


Die Casting Process in Google News:

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting, Die Casting Process Modeling

 


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