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Top 5 Tips for Die Casting

August 11, 2016

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Die casting can be a tricky thing to master. That’s why at Pace Industries, our experts are here helping through every phase of the process. Pace is constantly working to provide uncommon solutions to customers, and one example is the extensive product design assistance we offer.

We work with our customers on the design of their castings to incorporate features that will maintain functionality while optimizing features that enable the casting to be easier to produce. This allows our customers to receive a casting from Pace that is designed to minimize their cost while allowing Pace to minimize our production costs.

Customers often know what they want functionally and we know how to make a casting that will meet those needs. Here are our top five tips that can help you understand our process and the reasoning behind the design guidance we provide.

TIP #1: Maintain a uniform wall thickness across the casting. (While this is not always possible, try to keep the variations in wall thickness to a minimum.)

• This improves metal flow and the filling of the casting for better quality. It also minimizes dimensional variation due to the differences in cooling rates in the casting walls.

TIP #2: Corner radii (outside corners) and fillet radii (inside corners) on the casting should be as large as possible.

• This improves the filling of the casting for better quality and increases die life due to decreasing of the degradation of the die steel in sharp corner areas.

TIP #3: Include draft (tapered walls) in the casting design. You should have more taper (draft) on the inside walls of the casting than you do on the outside walls of the casting.

• Draft is required in order to remove the casting from the die. (This the same reasoning used in the design of muffin tins, which have tapered walls to aid in removing the muffins.) The reason for more draft on the inside walls is that the casting alloy shrinks as it solidifies. Castings tend to get smaller and fit more tightly onto the inside of the casting. The increased draft then allows for easier removal of the casting from the die.

TIP #4: Keep critical dimensions on the same side of the die.

• Since the die has moving components, dimensions that are based on more than one component will have more variation than dimensions that are based on features in a single die component. Greater variation in dimensions will require larger tolerances, which may not be acceptable to the function of the casting. When that happens, it requires added operations on the casting to meet tolerances, which will result in added costs to the customer. (Something we always want to avoid!)

TIP #5: Avoid undercuts, if possible.

• Undercut geometry cannot be cast in a standard die cast die. This undercut requires the addition of a moving die member called a “slide” in order to cast this piece of the casting geometry. The added “slide” increases the cost of the cast die. The undercut geometry also affects the amount of time required to make the casting, which increases the cost to the customer.

At Pace, we are here to provide hands-on assistance. We can help you understand the design process and what will ultimately be the best fit for your casting needs. We also offer casting design seminars at customer locations where we meet with product design engineers in an informal, educational setting to provide a better understanding of what designs work well for die casting.

Our first priority is always to provide our customers with high-quality products at competitive prices. Working together with our customers, we can help develop casting designs that satisfy functionality and castability requirements.DSC_8684

 

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Five Things You May Not Know About Aluminum

June 16, 2016

Five Things You May Not Know About Aluminum

When most people think of aluminum, it’s in reference to a soda can or long strips of foil used in the kitchen. An interesting thing about aluminum is that it’s actually found in many places, such as doorknobs, kitchen utensils and even glass production. And it continues to gain traction in many industries.

According to the Aluminum Association, it has been produced in commercial quantities for just over 100 years, which makes it a comparatively new industrial metal.

What makes aluminum so popular?

In addition to being the second most abundant metallic element in the Earth’s crust next to silicon, it’s easy to mold, fold and recycle. This creates a long list of benefits for things like packaging, transportation and construction.

With Pace being an aluminum die casting company, you can imagine our appreciation of this prevalent element. We believe the more that’s understood about the benefits and uses of aluminum the more we can innovate and advance technologies around this plentiful resource.

With that in mind, we’d like to share a few interesting facts.

  1. Aluminum is green. There are two types of aluminum: primary and secondary. Primary production is the process by which new aluminum is made. Secondary production is where existing aluminum is recycled into another usable form. This secondary process is extremely environmentally friendly. In fact, it’s 92 percent more energy efficient than primary production.With the ability to recycle aluminum so easily, there isn’t a high demand for mining new resources. The Aluminum Association reports that 75 percent of aluminum ever made is still in use. In our own operations, Pace uses only recycled aluminum. It’s more cost effective and also a responsible way to operate.
  1. Aluminum is extremely lightweight. According to the S. Geological Survey, it’s a third of the weight of steel or copper. What this means for Pace is that it allows us to have greater design capabilities. We can develop products that allow for lightweighting, which is critical for many of our customers – especially those in the aircraft, boating and automobile industries. Lighter machines translate to less energy required to operate.
  1. Aluminum plays well with others. The unique properties of aluminum alloy allow the metal to work well with a steel die, which is what Pace uses. The process moves quickly with aluminum, and we’re able to get fine details on a part. This can eliminate secondary operations and allow us to combine parts. That means less assembly for castings that are lower cost and with a finer detail.
  1. Aluminum was born out of science. Aluminum isn’t naturally found in the Earth’s crust. It comes from bauxite, which has to be processed to get aluminum. What this means is that it required the efforts of chemists and engineers to bring it to life. Essentially, innovation made this metal possible.As an interesting fact, Danish chemist Hans Christian Oersted first extracted aluminum from alum in 1825. It remained a novelty and too expensive to mass-produce until 1886 when American chemist Charles Martin Hall and French chemist Paul Héroult independently invented the Hall-Héroult process, which is still used today.
  1. Aluminum is getting stronger. Scientists continue to search for ways to improve aluminum, and there are currently hundreds of mixes on the market. One of the most recent breakthroughs was in 2010. Yuntian Zhu, a professor at North Carolina State University, and his colleagues subjected aluminum with magnesium and zinc to extreme pressure. The result was an aluminum that’s as strong as steel.The next phase of development is to produce this in large enough volumes for commercial applications, which will be a game changer for many industries.

With so many applications and unique benefits, it’s easy to classify aluminum as the metal of modern life. We’re excited to continue innovating with this resource and watch how it will transform the world around us in years to come.

For a complete history of aluminum, check out this article by the Aluminum Association.

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Getting a Handle on Quality

April 30, 2015

St. Paul Division wins 2014 Webasto Quality Excellence Award

By Darren J. Bombich
Sales Manager/Sales Engineer, Pace Industries’ St. Paul Division

Doug Winfrey (left) and I (right) accept the Webasto 2014 Quality Excellence Award from Webasto Buyer Dawn Bostwick
Doug Winfrey (left) and I (right) accept the Webasto 2014 Quality Excellence Award from Webasto Buyer Dawn Bostwick

Doug Winfrey (left) and I (right) accept the Webasto 2014 Quality Excellence Award from Webasto Buyer Dawn Bostwick

It’s the details that make the difference. Pace Industries St. Paul Division proved that recently by serving one of our customers with a unique need — and we were rewarded for it. Webasto-Edscha Cabrio USA,  a manufacturer of automotive convertible roof systems, came to us with a request that looked simple enough on the surface: Supply an overmolded and machined die cast aluminum operating handle for the convertible top on the new Ford Mustang. When they shared their need for a tight turnaround and approval time with us, that’s when things became a little more interesting.

As you can imagine, any component added to an automobile must go through a rigorous approval process by the vehicle manufacturer for safety and durability.  It was discovered early in the APQP process that Webasto had specified a neoprene-type overmold material that had not been approved by Ford. The customer was facing the reality that they might not be able to deliver a solution before the new Mustang was slated to hit the streets.

The St. Paul team was quick on our feet to come up with a solution. By thinking outside the box, we found a material that was already used elsewhere in the vehicle that we thought might also work for this application. We were right. Using this already Ford-approved material allowed the engineering change process to fast track, which solved Webasto’s timeframe problem. It also ensured they got parts at the price point they needed to provide a smooth, on-time launch for the new Mustang.

The hard work and ingenuity led to a solution that recently earned the St. Paul Division Webasto’s 2014 Quality Excellence Award. The two key elements that secured the quality excellence award: 100 percent on-time delivery and zero parts per million defects (PPMD). Pace was able to deliver both and exceed Webasto’s expectations. Doug Winfrey, quality control manager at the St. Paul Division, said it well:

“I am proud of St. Paul and was honored to stand up and receive this award for our team. Our success in our business, which contributed to the Quality Excellence Award, can be shown through the proper execution of Advanced Product Quality Planning (APQP).”

Full utilization of the APQP Workbook at St. Paul is partially to credit for the award. Of course, all those processes don’t mean much if there’s no one there to implement them, and our team stood up to the challenge.

Check out this video on the new Ford Mustang convertible, which includes highlights on the all-new convertible roof system and a look at the operating handle supplied by Pace’s St. Paul Division.

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Optimizing Cost through Early Supplier Involvement

April 16, 2015

John Scott Bull
Vice President of Sales & Marketing

Arnie Fulton
Vice President of Engineering

At Pace Industries, we pride ourselves on being a true partner with our customer. We’ve long recognized that we need to set ourselves apart from the rest in order to earn and keep your business. Our mission statement is to find uncommon, creative solutions that contribute to the success of our customers. One of the ways we do that is through our desire and ability to optimize cost for our customers.

Cost optimization can be achieved in a number of ways. We are committed to a lean manufacturing process whenever possible. By reducing waste, streamlining production processes and design, as well as improving workflow, our customers benefit by having reduced time-to-market and lower overall production costs. However, Early Supplier Involvement is where our greatest opportunity lies. By working early on with your engineers on the design activities, we can develop designs that are not only functional, but are also easier to cast. There have been multiple times that we have been brought into a project during the design phase and we have been able to reduce metal content, adjust shapes to improve productivity, and even offer alternatives like different alloys that would reduce the cost and meet customer criteria.

“We work with our customers to understand the function of part they want to design and provide design suggestions to achieve the functional requirements while incorporating features that are efficient to cast. In this way we satisfy our customer’s need for a functional part along with our need to have a design that satisfies the requirements for the die cast process.”

— Arnie Fulton, Vice President of Engineering

For example, we suggested a novel approach for a customer who had an automotive application. Typically, the part would be manufactured using a non-die cast process, but we felt that a die cast product would give them the functionality needed but at a lower cost of production. After we conducted casting design training sessions with their engineers and applied our education and expert guidance, we were able to show them how die casting would be a more cost efficient method of manufacturing for them.

In another instance, we worked with a lighting customer on a fast track LED project. At the time we were brought in, they already had a near final design. After review, we realized it wasn’t possible to manufacture the part in its current state. Following two days of discussion and revision, we were able to optimize the design for manufacturing, and remove more than two pounds of aluminum from the design, reducing the cost by several dollars.

Not every manufacturer has the capabilities to work with you in this way. We put a significant focus on working with our customers to find solutions to optimize cost. Being a full-service die cast company means we have the resources and technical expertise to partner with our customers early in the design phase and also once the part is in production. To truly optimize cost, you need more than a good price or a low margin. The value we provide in product design, weight reduction, keeping proper inventory levels on hand, close proximity to delivery locations, internal tool shops, good quality, and other benefits are what truly optimizes the cost of doing business with Pace versus other die casters.  We welcome the opportunity to show you how we can help you achieve the right balance of design, function and cost.

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The Benefits of Magnesium Die Casting

March 19, 2015

Jim Hegland
Director of Sales

My background in the die cast industry up until 1995 was centered on aluminum and zinc. About that time, I was offered an opportunity to work with some people who had a desire to start up a Magnesium Die Cast operation. It sounded exciting, but wait a minute; I didn’t know a thing about magnesium. I started reading and absorbing everything I could find on the subject and quickly realized most everything available at that time had been published 10 to 20 years earlier. The common denominator I came up with was that there were plenty of issues with magnesium – most notably, that magnesium burns at an incredibly high temperature and corrodes. At this point, I thought, this might be a tough sell.

It was difficult at first because we were centered on the challenges we had heard about and not on the positives, which we quickly realized. We soon began to see that the two main issues, flammability and corrosion, were only partly true. A lot of things burn and corrode, it’s all in how you process it and work with it. Both of these conditions have proven to be controllable and can be overcome with proper processes and techniques that allow you to focus on the significant benefits of magnesium.

The real benefits of Magnesium Die Cast fall into two categories: processing and material specific.

Processing Magnesium

In our business there are 2 basic style machines: Hot Chamber and Cold Chamber.

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The Hot Chamber Process we use has several benefits.

1) With Hot Chamber the molten metal is enclosed in a sealed furnace greatly reducing the risk of a fire. 2) With Hot Chamber the process time is 25-40% faster than the conventional Cold Chamber

3) Hot Chamber casting reduces recyclable scrap by 30-50% versus Cold Chamber.

4) Lower injection pressure, which equals better tolerance control for precision parts.

5) Hot Chamber casting prevents many porosity-type defects.

Material Benefits of Magnesium

The ability to cast fine details, plus the advantage of very thin wall sections gives magnesium a significant advantage over other castable metals. With magnesium, you have an automatic 35% reduction in mass/weight over aluminum. If you combine that with thinner walls you may be 50% lighter. These benefits give magnesium a clear advantage on highly cosmetic parts.

Our experience with magnesium has provided evidence that this material gives the best dimensional part-to-part consistency mostly due to the quick solidification time and a natural lubricity that keeps it from sticking in the mold.

Magnesium machines very nice and with the very low cutting pressure required; very close tolerances are achievable. This low-cutting pressure also significantly lengthens the life of perishable tooling such as end mills, taps and drills.

These benefits go beyond cosmetic parts. All of these advantages apply to many industries. In automotive applications, the fact that magnesium reduces vibration 25 times better than aluminum gives this material a clear advantage by reducing road vibration. Most steering wheels made today have a Magnesium core over-molded with vinyl. This improves driver comfort by stopping the vibration from reaching your hands.

In any other industry that requires very tight tolerances, magnesium can often times be less expensive than the other cast metals by eliminating machine operations and provide many “as cast” features. When you combine this with the fact that magnesium die cast tooling lasts 2-3 times longer than aluminum tooling, some tangible advantages start to develop.

At the end of the day, the customer is the ultimate decision maker on what material they use. Giving them the options is my job. Over the years, many of our associates have asked me, “Jim, why does this part need to be magnesium?” Being a sales guy, my answer is, “That’s what we do.”

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What the Heck is Die Casting?

March 5, 2015

static1.squarespace.comMy name is Eve Mayer and I don’t work in die casting. I am an author who works in social media, the world of words where everything we create can neither be touched nor felt with the human hand.

So, when I was invited (or rather, I invited myself) to tour the die casting factory of one of my company’s favorite clients, Pace Industries, I think they thought it was pretty odd.

The fact is I love factories because of my parents. For some strange reason, since I was little, they have brought me to see how all types of things are made; and because we are good eaters, it was usually food factories like Ben and Jerry’s or candy or potato chips. These experiences have allowed me to develop an appreciation and curiosity for manufacturing.

Although Pace had described in detail what they do, I just didn’t completely get it until I saw it with my own eyes. After all, die casting to the outside world sounds very ominous and foreign. So, the purpose of my tour was to understand – What the heck is die casting?

Die Casting is using a mold to make stuff out of metal. I’m probably not saying these terms by industry standards, but for those of us in the everyday world, I think that is what I learned that die casting is.

static1.squarespace1Die casting isn’t a glamorous industry. It is a detailed, precision necessary industry where hard working people use machines to carefully craft metal pieces like auto parts, light bulb bases, motorcycle pieces, back sides of carpeting and bed springs. My view is probably skewed as I toured an aluminum factory and die casting is done with several different types of metals like zinc, magnesium and aluminum.

For those of us in the world of creating intangibles, it is pretty cool to see things created that you can touch and feel. The process not only sounds interesting but also uses more necessary creativity than I would have expected.

Let’s say you need a piece of metal for a specific job. First, you must design it in such a way that it can accomplish this job. Next, you need to decide whether it should be forged or die cast. Die cast means that a mold will be created typically out of precision steel and split into two halves. These halves will be put together and held there by hydraulics while hot metal is injected into the mold and cools for up to one minute before the new metal piece is released.

After the piece comes out of the mold, it needs to be trimmed and polished. I thought the polish process was interesting because it basically looked like they put metal pieces into a big bowl of pink rocks and shook the metal piece around until the rough edges cam off.

static1.squarespace.comSome metal pieces need to be pretty and some don’t. For example, if you are having a piece built for the inside of a car engine that someone will never see once built, you don’t want to spend money on making this piece pretty, it just needs to be functional. Another metal piece might be on a motorcycle but sit on the outside of the bike in full view so it needs to be functional but also have a nice look to it. This is where specific processes that deal with painting or chroming parts comes into play.

As you might imagine, the mix of machines and people with high volume makes safety very important in die casting. Pace has an interesting view that has helped them dramatically increase their rates of on-the-job safety. A Pace executive believed that safety is a mindset that is constant – meaning that safety at home and on the job cannot be separated. He asked employees to make a personal safety pledge. Employees wrote down and posted safety commitments that were important to them in their own lives and posted them near the workspace. For example, “I will not text or make phone calls when I drive.” It was pretty inspiring to see these pledges for safety hanging on the wall and to hear about the positive effects this movement has had.

All in all, I really enjoyed my tour of a die casting facility. It was rewarding to see the entire process of how so many parts I take for granted are being made right here in the USA. And for us regular Joes, the answer to “What the heck is die casting?” is – it is the process of making metal pieces out of a mold. See, it’s not that scary after all.

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