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Design of a high pressure die cast tool
Axis - IT&T created a high pressure die-casting tool for
four impressions - one for each of the components.
An Australian pressure die-casting manufacturer wanted to manufacture
four different types of zinc components, which were similar in
shape. They had a two-impression tool for the simultaneous production
of two of the four components.
To enhance the production of the components, the client wanted
to have a single pressure die-casting tool, designed with four
impressions - one for each of the components.
Axis-IT&T was given 15 working days to complete the tool
design along with assembly data and manufacturing drawings.
Inputs given by the customer:
- CAD models of the four components
- Metrics of the pressure die casting machine
- Images of the existing two-impression pressure die casting
tool
- List of all standard hardware items being used
- Details of the tool design standards being followed
Delivery:
The tool layout along with the orientation of the four components
was created and proposed to the client for their suggestions and
approval. The tool had four inserts in the fixed half, four inserts
in the moving half and a total of eight sliders, four on each
side.
Based on the comments of the client, modeling of the core, cavity
and sliders was done in Unigraphics.
The design and analysis of the runners, position of gates and
analysis of the cooling circuit is quite important for pressure
die casting tools. The client had agreed to support the company
with the design for the runners, location of the gates, as well
as, design of the cooling lines. The basic assembly drawing of
all the inserts was sent to the client for getting these data,
as well as for approval of the basic assembly drawing of the tool.
The assembly model was created using the WAVE concept,
in which part models were linked to the assembly model. Any modification
in the part would trigger an automatic update to the drawings.
Complete mating conditions were specified in the assembly model.
The drawings were created through Interpart expressions, in which
the feature parameters of the model were linked to the drawing
notes. An update on a feature parameter of the model would trigger
an automatic update to the linked drawing note.
Customer's benefits:
- Reduction in detailing time
- Savings in detailing cost
The Axis-IT&T off-shore team worked as an extended modeling
facility for the customer with the customer having online access
to the project developments.
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