Center for

Die Casting

Computational Tools for Short Run Insert

Production and Improved Yield
Ohio State University/NADCA
R. Allen Miller

AMC
Castings for Improved Readiness

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 Center for
Status Die Casting

AMC Castings for Improved Readiness

(CIR) project
Officially started June 2006

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 Project Objective Center for
Die Casting

The problem
DLA needs cast parts rapidly and in low volumes
Die casting is a high volume process with long
tooling lead times
The objective
Optimize the insert and die to meet quality
specifications while using modular components to
shorten lead times and reduce break-even point
Optimize shot yield by managing runner system
design
The technology will
Match modular die components with parts and inserts
reducing the number of die components that must be
fabricated
Optimize runner design so modular tooling does not
impose a quality or yield penalty
Aid in configuring die to improve/optimize shot yield

Ejector die built with

a unit die base

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 Center for
Needs and Benefits Die Casting

DoD / Supply Centers

Die castings feasible for short-run production (100 200 +)
Increase size of the supplier base
Shorter design / production lead times for die castings
Lower cost castings due to
Lower tooling cost
Higher yield and lower melting costs

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 Center for
Die Casting
Needs and Benefits

Metalcasting Industry
Break even at lower total production quantities for die
castings
Lower tooling cost with reusable modular components
Minimization process degradation typical with modular components

Less on-machine process debugging associated with modular

tooling
Significantly reduced tooling lead time when combined with
rapid tooling
Higher shot yields
Lower unit material and melting costs

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 Center for
Tasks Die Casting

1. Yield Improvement (current work)

Visualization approach yield feedback provided for user
Optimization suggestions for yield improvement

2. Short-run Holder Block Selection (scheduled to

start mid 2008)
Group technology/database approach
Match insert to base depending on part features

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 Center for
Project Progress Yr 1 Die Casting

Completed review of part quality/die design

constraints
Map of design variables and defects/quality constraints
Map sets constraints for layout and yield
Map also provides constraints for modular tooling work that
will start next year
Started visualization software for shot yield
determination. Features include:
Configure die
Layout runner system
Quantify shot yield versus part requirements

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 Center for
Yield Improvement Die Casting

Yield = Casting Wt / Shot Wt

Shot Wt = Casting Wt + Biscuit/Sprue +
Runner + Overflow + Flash
Casting Wt = Finished Part Wt +
Machining Allowance
Machining allowances & flash not
considered in this work

Yieldimprovement largely means

optimizing biscuit, runners and overflows

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 Center for
Technical Problem Die Casting

Provide software to help determine the

part/die configuration that results in the
highest yield subject to the gating constraints
and machine availability

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 Center for
Yield Approach Die Casting

1. Visualization (low difficulty)

Adjustments are input interactively and yield, flow
distance, and fill time are fed back
User makes changes interactively
2. Optimization (high difficulty)
Algorithm makes translations and rotations in 3-
space seeking higher yield, shorter fill distances, and
minimum number of gates
Depends on feasibility of some type of ejectability
analysis

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 Center for
Progress Die Casting

Quality vs. Yield

Quality PQ2 is the best available way to
Part Geom.
Specs relate quality requirements to
die/process design (fill time, gate
PQ2 velocity, static pressure).
Fill Time
& Gate Vel Fill time and gate velocity largely
control surface finish and porosity
Biscuit volume and runner layout
Runner determine yield
Yield
Layout Die configuration and gate area
controls the runner layout
Insert Plunger selection and runner
Layout layout are the primary levers to
control yield
Die Base

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 Injection System & Quality
Relationships

Metal pressure and metal flow rate

control surface finish, porosity,
casting integrity i.e. control quality
Machine determines power
available
Plunger size and machine control
flow rate and also pressure on metal
Gate area and machine operating
point control metal speed thru gate
Plunger size determines biscuit size
that contributes to yield

PQ2 Diagram Relating Machine, Die and Gating

 Center for
Major Constraints/Limits Die Casting

Machine availability
Sleeve availability
Fill requirements (control fill
defects)
Surface finish
Consistency across cavities
Possibly solidification pattern

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 Center for
Key Factors Die Casting

Biscuit
Sleeve selection controls diameter
2.5 sleeve vs. 2.0 56% larger volume for same length
Sleeve should be optimized based on requirements
Process control controls biscuit length
Runner System
Depends on die layout
Fill zone requirements control number of gates
Gate dimensions and location plus layout control
runner layout

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 Summary Center for
Runner System and Quality Die Casting

Runner big factor in yield

Runner must connect gate to part
Gate locations and size determined by fill pattern
requirements that impact trapped gas porosity and surface
finish
More gates means more runner volume and lower yield
More gates often used to reduce distance metal must flow to fill cavity
(reduce chance of premature solidification and fill defects)
Total gate size determined by machine and metal gate speed
requirements
Match machine power to part requirements (see figure on previous slide)
Opportunity is to improve part layout in die to improve the
runner system to improve both yield and performance

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 Center for
Runner Layout for Visualization Die Casting

Quadratic spline
techniques implemented
to aid runner system
layout
Fast and easy generation
of alternatives
Immediate yield feed
back while meeting gate
area (quality)
constraints

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 Example What should happen

Part should be rotated 180 degrees

Kicker gates removed eliminating the outside runners
Main gates increased in size to accommodate the other changes
Depending on machine, biscuit could be moved closer to the part to
shorten runner
 Center for
Short Term Plans Die Casting

Visualization work for yield will be

completed.
Testing before and after yield and quality
results for at least 3 dies

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 Center for
Short term Plans Cont Die Casting

Existingqualitative ejectability analysis

algorithms will be implemented
Die layout affects ejectability as well as yield
Visual and quantitative feedback of the
ejection force distribution on the part will be
provided
User of the software will be able evaluate
yield/ejection tradeoffs

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 Center for
Mid Term Die Casting

Explore optimization/design guidance

for yield and quality

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 Center for
Longer Term Die Casting

Holder block matching and selection

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 Center for
Acknowledgements Die Casting

AMCs PRO-ACT program is sponsored by

the Defense Supply Center Philadelphia,
Philadelphia, PA, Defense Logistics Agency, Ft.
Belvoir, VA

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