Moving Out of the “Stone Age”

Moving Out of the “Stone Age” Today we make our tools betterWhy do they not last as well as we make them? What are we missing? North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Past Logic No Longer Applies We keep using the same build techniquesWe keep getting the same results North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Time for a new approach Time for a new approach MPCMP MPCMP Get the Flow withoutthe stress North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Failures at fillets and radii Rocker Arm Casting Stoning these areas of the die, scratch the surfaceof the tool which invite failures to occur“Harley Davidson has proved this” North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Failures at fillets and radii Fillets and Radii stoning are thefirst place where die failures occurs“Harley Davidson has proved this”NADCA Orlando 2010 - T10-062 North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Residual Stress Build Up NADCA Baseline Study At 100 cycles not visibleAt 15,000 cycles visibleIsn’t this how your toolingfails? North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Stoning + Diamond + MPCMP XL Inner Rocker • XL Inner Rocker Arm – Sigma 6 Project • High Cosmetics – Rejects at approx 12,000 shots • Procedure: Prior to any use or production • Stoned, Diamond, MPCMP processing 29,000+ shots with acceptable parts • 100%+ improvement North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Stone Age Logic v/s The Facts • Fillets and Radii are where first signs of fatigue occur • Failure areas quickly spread to other areas • Resultant cracking and cavitation breakout • Stoning is done to improve casting flow characteristics • Stoning creates the stress risers in Fillets and Radii • areas that weakens the steel’s fatigue characteristics • Advancements in technology allow accurate finish machining that does not require sampling • Cutter marks and stoning removed from surface with proper diamond polishing to fillets and radii • Surface Engineering MPCMP after this North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Stoning v/s Diamond Polishing Stoned surfacewith stress risers Proper diamond polishno stress risers • Not all diamond polishing is created equal • Proper procedure is a skilled art • Only fillets and radii need be done North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Gains to be expected Eliminate the “No Time” “No Money” Excuses • Save on tool building cost • Increase the life of tooling • Improve Flow of molten metal • Eliminate porosity problems • Reduce fatigue cracking especially in the critical fillets and radii areas • Buffer Cavitation Breakout of die steel North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Why do die steels breakout? Erosion, pitting, and washout from cavitation* occur in the opposite locations where they would be expected. On the low pressure side of gate, and low pressure side of flow. *Recommended reading – NADCAPaper-T10-051-Cavitation Effect North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Cavitation Buffering Benefit Impossible to receive from other surface engineering treatments Normally any vacuum cavitation voids (bubbles) collapse on the surface with each shot. This leads to fatigue of the impact area. With introduction of a buffered surface, these same bubbles collapse on retained lubricant or molten cooling metal and dissipate their energy into this renewable media instead of on the die’s surface.Try that with a coating or diffusion process North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

We have always done it this way That my friends is the problem Today it is time to “Move out of the Stone Age” North American Die Casting Association Die Casting Congress & Tabletop - September 19-21, 2011 Columbus, OH USA

Moving Out of the “Stone Age”