Decision and Design Methodologies for the Lay-Out of Modular Dies for High-Pressure-Die-Cast-Processes

Abstract

Within the project “Decision and design methodology for the lay-out of modular dies” which is part of the Cluster of Excellence “Integrative Production Technology for High-Wage Countries”, established and financed by the German Research Foundation (DFG), the main objective is setting guidelines for cost-effective and high quality high pressure die casting (HPDC) moulds. The strong increase in product variants and the growing demand for individualised products results in a growing complexity of all related products. The main objective of this project is bridging the existing gap between individual manufacturing and mass production. A new perspective on the value creation chain of HPDC-dies has to be established. First of all, the methodology for the lay-out of modular dies consists in an analysis of the already produced die cast moulds. For the development of modules, standard parts, and different die types, a wide range of HPDC-dies will be compared with each other and subsequently clustered along specific criteria such as size or number of core sliders. Another step consists in optimising setting-up time and maintenance. The as-is state in different companies will be examined. With this knowledge, new concepts will be developed, keeping a modular configuration of the different parts involved in mind. Concepts for modular core sliders, guides and ejectors will be developed and will be investigated for further use. Based on this information, the decision and design methodology for the lay-out of modular HPDC -dies will be examined and developed throughout the process.