Using this analysis, tooling was produced and tested. In the resulting casting no failure was observed during testing, and x-ray inspection showed nearly no remaining porosity due to entrapped gases, so that the castings were within the specification. With the two-cavity die, the scrap rate could be significantly decreased to 2%. The annual production of 100,000 quality parts now saves 20 tons of raw materials and an estimated total of 95,000 to 110,000 US$ per year.
As this example shows, optimizing tooling design and process conditions with the methodology of virtual experimentation and autonomous optimization is an important step for CDM. The company will continue to use MAGMA5 Rel. 5.3 to further speed up R&D, establish robust and optimized casting processes, and expand their product portfolio.
Chongqing Dajiang Millison Co. Ltd., located in Banan, China, was founded in May of 2001. Millison has earned their customers’ recognition through accurate production and high quality products. Today, the company’s production bases are two plants in Chongqing and Xiangyang. Its annual output of aluminum castings reached 40,000 tons in 2013. Among others, they produce automotive die castings such as engine blocks, automatic transmission cases and structural parts on more than 50 machines ranging from 300 to 3,500 tons and have an in-house park of more than 300 CNC lathes and machining centers. The company is a renowned supplier for Ericsson and Shenlong and exports to Asia, Europe and the Americas.
* Text and images courtesy of Chongqing Dajiang Millison Co. Ltd., P.R. China