12Feb

Aluminum Die Casting: Inherited Die Discussion

Inherited Die: Moving Production

Over the past years, many customers have sent us a request for quote for a part which was already tooled up as a die casting. The customer usually has a problem with the current source whether it be a cost, quality, delivery or service problem.

In the past 6 years, there have been instances where the die cast vendor has ceased operations and the customer is in a rush to move tooling and production to another supplier. Regardless, it comes to a point where the customer mustmove the production to another vendor to secure their supply of die castings.

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Quoting the Existing Die Cast Part

This is not the most desirable situation for the new die caster. They have to quote an existing production die casting part with existing tooling, along with a number of variables such as:

  1. Usually, there is no access to a mold drawing to show the size and type of mold. Having a mold drawing or even sizes will confirm the mold will fit on the die caster’s machine without a large conversion cost. The die may need to be put into a different type of die casting machine than the current source
  2. Quality problems stemming from marginal tooling design. Quite often customers purchase die cast tooling based on price and only after the production begins do they learn that the mold is not capable of producing parts to exacting tolerances or cosmetic criteria.
  3. Quality issues with deterioration of the die steel and premature steel failure. This is true if the original mold cost was very low and below other competitive bids – it seemed too good to be true at the time of purchase, and it is.
  4. The die’s gate and runner system may also need to be modified to fit the new machine conditions or to improve metal flow and quality of the castings.

The die should be evaluated by the customer and the die caster’s tool room superintendent to assure that there are no visual problems with the die. They should also determine whether the die arrived with any required limit switches and hydraulic cylinders. Upon this review, an adaptation cost can be established and agreed upon before the receiving die caster has invested a large amount of time and expense in preproduction work.

The Checklist

Checklist T-2-1, which follows, will aid in discussions between the customer and the die caster regarding the important considerations in the produc­tion of parts from “inherited” tooling.

Note that with transferred, or “inherited,” tooling for die casting production the existing die casting die, the trim die, and, if required, the secondary machining fixtures, must be available for review and evaluation to determine whether the dies and fixtures are capable of producing to specifications and the extent of maintenance and/or rework required before the onset of production.

This would include any adaptations of the die caster’s equipment to accommodate production using the inherited dies.Final production estimates will be based on this review.

Inherited Die

Die Casting Die Available for Evaluation

Die to be Available for Evaluation (date):

Inherited Trim Die

Trim Die Not Required

Trim Die Available for Evaluation

Trim Die to be Available for Evaluation (date):

Inherited Machining Fixtures

Special Machining Fixtures Not Required

Machining Fixtures Available for Evaluation

Machining Fixtures to be Available for Evaluation (date):

Actual Casting Weight

Weight of Actual Casting:

Size of Die Size of Casting Die (for equipment limitations):

Weight of Die Weight of Casting Die (for crane limitations): 

Availability of Die Design

Yes

No

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Premier Die Casting

Premier Die Casting Company has been in business 69 years and has a diverse customer base and serves many industries and markets. Today Premier is growing and hiring new employees to meet the demands of the growing global economy.

Premier utilizes state of the art equipment in manufacturing high-pressure aluminum die castings such as Kawasaki robots, VisiTrak process monitoring systems, Mokon die temperature control systems, vacuum die casting, and a central lubrication system for the die spray.

If you have any parts you would like Premier to review, please send your drawings or files to lc@diecasting.com

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