TCG

The process development is most efficient in case of regular and close communication between the customer and our team. Starting with the specifications in the form of quality definitions and physical properties the manufacturing concept includes a numerical casting simulation, during which problematic or critical areas are identified and alternatives and possible cost-effective solutions proposed. Areas which need to be machined are determined and the convenient machining concept selected and proposed. The die-casting mould concept has a very strong influence on the part quality. Parameters such as number of cavities, locking force, runner and gating system, venting concept, casting and mould temperature, machine parameters and the flow characteristics of the specific alloy have to be determined. With the help of simulation tools, we are able to verify the assumptions of the die mold concept and identify further optimization potentials. Our experienced tool designers implement these inputs. During the sampling process the process parameters are fixed to ensure an efficient volume production.

Part requirements

• Definition of physical properties
• Definition of quality

Manufacturing concept

• Feasibility /Castability check (Simulation)
• Determination of casted / machined areas

Die concept/Injection mold concept

• Die-casting mold calculations
• Number of cavities
• Size of die casting machine
• Inlet position
• Runner and gating system
• Venting concept
• Cooling System

Simulation

• Die filling
• Solidification
• Verification of assumptions
• Identification of further optimization potentials

Detailed design

Sampling process

• Determination of the final process parameters

Volume production