Design for Zinc Die Casting


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  • Design for Zinc Die Casting

    1. 2. Product Design for Die Casting <ul><li>Welcome! </li></ul><ul><li>Introduction </li></ul><ul><ul><li>The North American Die Casting Association </li></ul></ul><ul><ul><li>NADCA Design </li></ul></ul><ul><ul><li>Your Speaker </li></ul></ul><ul><ul><li>Design and Development </li></ul></ul><ul><ul><li>Introduce Yourself </li></ul></ul><ul><li>Resources </li></ul><ul><li>Geometry Optimization </li></ul><ul><li>Assemblies </li></ul>
    2. 3. North American Die Casting Association (NADCA) <ul><li>Industry trade association for: </li></ul><ul><ul><li>Die casters </li></ul></ul><ul><ul><li>Suppliers </li></ul></ul><ul><ul><li>Consumers of die castings </li></ul></ul><ul><li>Primary objectives of NADCA </li></ul><ul><ul><li>Education </li></ul></ul><ul><ul><li>Research and development </li></ul></ul><ul><ul><li>Growth of the die casting Industry </li></ul></ul>
    3. 4. NADCA Design Assistance Program <ul><li>In short form: “NADCA Design” </li></ul><ul><li>Established by NADCA to: </li></ul><ul><ul><li>Provide die casting product design assistance </li></ul></ul><ul><ul><li>Provide design and purchasing resources </li></ul></ul><ul><ul><li>When Appropriate: </li></ul></ul><ul><ul><ul><li>Increase the use of die castings </li></ul></ul></ul><ul><ul><ul><li>Expand the markets for die castings </li></ul></ul></ul>
    4. 5. Your Speaker <ul><li>15 years in metal casting industry </li></ul><ul><ul><li>Nonferrous sand casting </li></ul></ul><ul><ul><ul><li>Cleaning, polishing, machining, welding </li></ul></ul></ul><ul><ul><li>Die casting </li></ul></ul><ul><ul><ul><li>Engineering Assistant, Process Technician, Process & Manufacturing Engineer, Die Designer </li></ul></ul></ul>
    5. 6. Your Speaker <ul><li>Die Cast Product Design </li></ul><ul><ul><li>Conversion from other processes </li></ul></ul><ul><ul><li>Design for die casting </li></ul></ul><ul><ul><li>Product design </li></ul></ul>Die cast articulating wall arm for 32&quot; to 50&quot; LCD and Plasma Screens weighing up to 150lbs. Image courtesy of Peerless Industries Inc. ©2008
    6. 7. Your Speaker <ul><li>NADCA </li></ul><ul><ul><li>Design Engineer </li></ul></ul><ul><ul><ul><li>Design assistance </li></ul></ul></ul><ul><ul><ul><li>Update design materials </li></ul></ul></ul><ul><ul><ul><li>Instruct </li></ul></ul></ul><ul><ul><ul><li>Work with other organizations </li></ul></ul></ul><ul><ul><li>When beneficial, promote the use of die cast products </li></ul></ul>
    7. 8. Design and Development <ul><li>Good design & development = </li></ul><ul><ul><li>Smooth project </li></ul></ul><ul><ul><li>Better communication </li></ul></ul><ul><ul><li>High performance result </li></ul></ul>“ NADCA 1” Specimen Die Design. Six ASTM specimens are die cast in one shot (cycle) by this die casting die. The die produced good specimens the first time it was loaded into the machine to run. The design allowed smooth communication between the NADCA Design Engineer, the tool maker, a die casting plant, and university personnel that ran the test specimen project. This die will be used for specimen production for future NADCA research projects. Automated Die Casting Cell Design. This design allowed plant personnel to determine if automation equipment could be installed in the given space. The design shown allowed smooth communication between the Manufacturing Engineer, Maintenance Mechanics, the owner, other engineers and shop floor employees, so they could be involved with and give feedback on the project.
    8. 9. Design and Development <ul><li>Poor or no design / development = </li></ul><ul><ul><li>Rough project </li></ul></ul><ul><ul><li>No or difficult communication </li></ul></ul><ul><ul><li>Low performance result </li></ul></ul>
    9. 10. Design and Development <ul><li>Cost of Design </li></ul><ul><li>&quot;Most companies spend only 5 percent of their budget on design, but design typically accounts for 70 percent of the cost of the product -- partly because 80 percent of quality problems are unwittingly designed into the product itself.“ </li></ul><ul><li>Chowdhury S. (2002). Design for six sigma: The power of. New York: Kaplan. </li></ul>
    10. 11. Introduce Yourself! <ul><ul><li>Name </li></ul></ul><ul><ul><li>Position, Department </li></ul></ul><ul><ul><li>Background </li></ul></ul><ul><ul><li>Interests </li></ul></ul>
    11. 12. Resources <ul><li>Product Design for Die Casting Book </li></ul><ul><ul><li>123 page source book </li></ul></ul><ul><ul><li>Base of this seminar </li></ul></ul><ul><ul><li>Copies provided </li></ul></ul><ul><ul><li>Part of the NADCA Design Program </li></ul></ul><ul><ul><li>Order additional copies from the NADCA Design website </li></ul></ul>
    12. 13. Resources <ul><li>NADCA Design Website </li></ul><ul><ul><li> </li></ul></ul><ul><ul><li>Product Development </li></ul></ul><ul><ul><li>Part Design </li></ul></ul><ul><ul><li>Alloys </li></ul></ul><ul><ul><li>Instant Support </li></ul></ul><ul><ul><li>Info on this Seminar! </li></ul></ul><ul><ul><li>NADCA Standards </li></ul></ul><ul><ul><li>Additional Resources </li></ul></ul><ul><ul><li>Find a Die Caster </li></ul></ul><ul><ul><li>Die Casting Examples </li></ul></ul><ul><ul><li>Design Publications </li></ul></ul>
    13. 14. Resources <ul><li>NADCA Publications </li></ul><ul><ul><li>Product Specification Standards for Die Castings #402 </li></ul></ul><ul><ul><li>Product Specification Standards for Die Castings Produced by the Semi-Solid and Squeeze Casting Processes #403 </li></ul></ul><ul><li>NADCA Software </li></ul><ul><ul><li>CastView </li></ul></ul><ul><ul><ul><li>Thickness Analysis </li></ul></ul></ul><ul><ul><ul><li>Thin Die Analysis </li></ul></ul></ul><ul><ul><ul><li>Filling Pattern </li></ul></ul></ul><ul><li> </li></ul><ul><ul><li>/publications </li></ul></ul>
    14. 15. Resources <ul><li>NADCA Product Specification Standards for Die Castings #402 </li></ul><ul><ul><li>1 Process and Material Selection </li></ul></ul><ul><ul><li>2 Tooling for Die Casting </li></ul></ul><ul><ul><li>3 Alloy Data </li></ul></ul><ul><li>Engineering and Design </li></ul><ul><ul><li>4A Coordinate Dimensioning </li></ul></ul><ul><ul><li>4B Miniature Die Casting </li></ul></ul><ul><ul><li>5 Geometric Dimensioning </li></ul></ul><ul><ul><li>6 Additional Specification Guidelines </li></ul></ul><ul><ul><ul><li>For tolerancing / drawings </li></ul></ul></ul>
    15. 16. Resources <ul><li>NADCA Product Specification Standards for Die Castings #402 </li></ul><ul><ul><li>7 Quality Assurance </li></ul></ul><ul><ul><li>8 Commercial Practices </li></ul></ul><ul><ul><ul><li>Checklists </li></ul></ul></ul><ul><ul><ul><li>For quoting stages </li></ul></ul></ul><ul><ul><li>9 Casting Examples </li></ul></ul><ul><ul><li>10 Index / Glossary of Die Casting Terms </li></ul></ul><ul><li>One copy provided for seminar </li></ul><ul><li>Latest PDFs downloadable at: </li></ul><ul><ul><li>Print and CD version also available </li></ul></ul>
    16. 17. Product Design: Geometry Optimization <ul><li>Draft </li></ul><ul><li>Fillets </li></ul><ul><li>Parting line </li></ul><ul><li>Bosses </li></ul><ul><li>Ribs </li></ul><ul><li>Holes & Windows </li></ul><ul><li>Symbols </li></ul><ul><li>Uniform Walls </li></ul><ul><li>CAD Feature Order </li></ul><ul><li>Assemblies </li></ul>
    17. 18. Product Design: Geometry Optimization <ul><li>Transformation of geometry to get: </li></ul><ul><ul><li>Improved product performance </li></ul></ul><ul><ul><li>Die castable design </li></ul></ul>
    18. 19. Geometry Optimization: Draft <ul><li>Required for surfaces perpendicular ┴ to the opening of the die. </li></ul><ul><li>Draft is taper that </li></ul><ul><ul><li>Allows die opening </li></ul></ul><ul><ul><li>Allows casting removal </li></ul></ul><ul><ul><li>Reduces ejection force </li></ul></ul><ul><ul><li>Prevents bending </li></ul></ul><ul><ul><li>Improves surface quality </li></ul></ul><ul><ul><li>Increases die life </li></ul></ul>
    19. 20. Geometry Optimization: Draft <ul><li>Draft different for </li></ul><ul><ul><li>Inside walls </li></ul></ul><ul><ul><li>Outside walls </li></ul></ul><ul><ul><li>Holes and windows </li></ul></ul><ul><ul><li>Cored holes </li></ul></ul><ul><li>Levels </li></ul><ul><ul><li>Standard </li></ul></ul><ul><ul><li>Precision </li></ul></ul><ul><li>Low or zero draft </li></ul>
    20. 21. Geometry Optimization: Draft <ul><li>Basic Draft Video </li></ul>
    21. 22. Geometry Optimization: Draft <ul><li>Draft Calculation </li></ul><ul><ul><li>For Std draft angle </li></ul></ul><ul><ul><li>A=57.2738/C √ L </li></ul></ul><ul><ul><li>A is angle </li></ul></ul><ul><ul><li>C is constant from chart </li></ul></ul><ul><ul><li>L is the depth or height of the drafted feature </li></ul></ul><ul><li>Lower L values = higher draft angles </li></ul>
    22. 23. Geometry Optimization: Draft
    23. 24. Geometry Optimization: Draft <ul><li>Advanced Draft Video </li></ul>
    24. 25. Geometry Optimization: Draft <ul><li>Draft Analysis </li></ul><ul><ul><li>Available in many CAD packages </li></ul></ul><ul><ul><li>Color codes +, - and zero draft walls </li></ul></ul><ul><ul><li>Highlights parting line </li></ul></ul><ul><ul><li>Identifies side action pulls </li></ul></ul><ul><ul><li>Helps develop flash removal procedure </li></ul></ul><ul><li>Advantages </li></ul><ul><ul><li>Helps finalize design </li></ul></ul><ul><ul><li>Increases quote accuracy </li></ul></ul><ul><ul><li>Simplifies die design process </li></ul></ul>
    25. 26. Geometry Optimization: Draft 3 ° 0.5 ° <ul><li>Simple part example: knob </li></ul>
    26. 27. Geometry Optimization: Draft <ul><li>Complex part example </li></ul>1 °
    27. 28. Geometry Optimization: Fillets <ul><li>Overview </li></ul><ul><ul><li>Fillet sharp corners and edges </li></ul></ul><ul><ul><li>Fillet even the smallest features </li></ul></ul><ul><ul><li>Parting line may be left sharp </li></ul></ul><ul><li>Advantages </li></ul><ul><ul><li>Strengthen part </li></ul></ul><ul><ul><li>Extend die life </li></ul></ul><ul><ul><li>Improves metal flow </li></ul></ul><ul><li>Disadvantages </li></ul><ul><ul><li>May create thick or thin sections </li></ul></ul><ul><ul><li>Difficult to apply to complex geometry </li></ul></ul>
    28. 29. Geometry Optimization: Fillets
    29. 30. Geometry Optimization: Fillets
    30. 31. Geometry Optimization: Fillets
    31. 32. Geometry Optimization: Fillets
    32. 33. Geometry Optimization: Fillets <ul><li>Fillets Video </li></ul>
    33. 34. Geometry Optimization: Parting Line <ul><li>Parting Line Video </li></ul>
    34. 35. Geometry Optimization: Bosses <ul><li>Boss information will go here </li></ul><ul><li>Boss video will be shown </li></ul>
    35. 36. Geometry Optimization: Ribs <ul><li>Rib info will go here </li></ul><ul><li>Rib video will be shown </li></ul>
    36. 37. Geometry Optimization: Holes and windows <ul><li>Holes and windows will go here </li></ul><ul><li>Holes and windows video will be shown </li></ul>
    37. 38. Geometry Optimization: Symbols <ul><li>Guidelines for adding symbols like text and logos will be presented </li></ul><ul><li>Symbol video will be shown </li></ul>
    38. 39. Geometry Optimization: Uniform walls <ul><li>Goal is uniform wall thickness </li></ul><ul><li>May effect casting quality </li></ul><ul><li>May effect die life </li></ul><ul><li>Very thin walls may not fill </li></ul><ul><li>Thin walls may freeze earlier </li></ul><ul><li>Thick walls may increase cycle </li></ul><ul><li>Thick walls may promote defects </li></ul>
    39. 40. Geometry Optimization: Uniform walls <ul><li>Thin section analysis results </li></ul>
    40. 41. Geometry Optimization: Uniform walls <ul><li>Thick section analysis results </li></ul>
    41. 42. Geometry Optimization: Uniform walls <ul><li>Thin die sections </li></ul><ul><ul><li>Different than thin part section </li></ul></ul><ul><ul><li>Think negative image of part </li></ul></ul><ul><ul><li>Caused by part geometry </li></ul></ul><ul><ul><li>Reduces die life and increases die maintenance costs </li></ul></ul>
    42. 43. Geometry Optimization: Uniform walls <ul><li>Thin die section analysis results </li></ul>
    43. 44. Geometry Optimization: Uniform walls <ul><li>Uniform Walls Video </li></ul>
    44. 45. Geometry Optimization: CAD feature order <ul><li>Recommended order </li></ul><ul><li>Allows changes with less errors </li></ul><ul><li>Helps create cast and machined models </li></ul><ul><li>Saves Time </li></ul>
    45. 46. Geometry Optimization: CAD feature order <ul><li>Base Geometry Features </li></ul><ul><li>Cast Cored Holes </li></ul><ul><li>Parting Lines </li></ul><ul><li>Draft </li></ul><ul><li>Fillets </li></ul><ul><li>Machining </li></ul>
    46. 47. Geometry Optimization: CAD feature order <ul><li>CAD Feature Order Video </li></ul>
    47. 48. Assembly Consolidation <ul><li>Info on assemblies will be presented here </li></ul>
    48. 49. Assembly Consolidation <ul><li>Assemblies Video </li></ul>
    49. 50. Conclusion <ul><li>Thanks for Listening! </li></ul><ul><ul><li>Introduction </li></ul></ul><ul><ul><li>Resources </li></ul></ul><ul><ul><li>Geometry Optimization </li></ul></ul><ul><ul><li>Assemblies </li></ul></ul>