Define what the customer wants and have standard approach to what the process can normally 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.
For information on purchasing a downloadable copy of this webinar in its entirety, please visit: diecasting.org/store/detail.aspx?id=WEB316
"So to stop warpage, do not reduce die thickness. It will probably give you more problems, which cost dollars. We had a die that was nearly a meter wide, three feet wide. The die was only three inches thick and they wanted high dimensional accuracy. Impossible. Cannot achieve it, cannot achieve it. Bolt the cavity inserts to the mold base or holder. More of this on later webinars or, if you get the book, the final chapters.
How you bolt it down is important. We are talking about huge loads on a die. If you think of a 600-ton machine, take your dye and put 400 cars on top of that die, that's the loading it has to take. 400 cars on top of just your die, so if you've got a reasonably sized car park, take all those cars, and put them on top of your die. These are the loads that we have, just a 600 ton.
Do not heat the die using a strong blue flame. As the die heats up, the die will walk. Use a designed cooling system to maintain a good temperature profile, and I said we've got a simple method of doing it, very little math involved now.
So to assure that tooling does not require welding during the initial tool-sampling phase, it's best to design dimensions to be steel safe. You do not want to weld up a die. I will do anything to try and stop welding up a die. The cavity dimension should always be on the small side. Cores and pins should always be on the large side so you can reduce them. Center lines should be nominal.
You try everything you can so that if you have to do anything, it's metal off the die, not metal on.
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."
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