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Short Run Tooling Requirements

W H I T E

P A P E R

Short Run Tooling Reqirements

Introduction
Advances in rapid tooling methods are creating opportunities for product designers and die casters to create cost-effective dies from a variety of materials using a variety of processes for low volume production runs. These methods are proving valuable in many situations. These include production of parts for military, aerospace and medical applications where demand may range from 1,000 to 10,000 pieces. Two requirements affect the selection of short run tooling. The first requirement is a need for rapid tooling. This allows for tools to be made quickly. Short lead times are clearly desired if small quantities of production parts are needed, or an interim source of products is needed while longer run tooling is completed. The second factor is the high cost of premium tooling can be a deterrent by offering larger capacity than needed. This creates a situation where die casting may be the ideal process for manufacturing the component, but since hundreds of thousands of parts are not required it is rejected as a viable and cost effective process. By utilizing different die materials the cost of the die is reduced allowing for short production runs. In addition this allows the process to be optimized for future longer runs. The current state of the art satisfies both of these requirements. Certain die materials have reduced the breakeven point of a die insert to 100-1000 shots from tens of thousands of shots. Rapid tooling methods exist that when coupled with 3D modeling has reduced the tooling lead time to 3-4 weeks. By combining these elements die casting, a traditionally inflexible process, can be flexible for shorter runs. Complex parts often require complex tool designs. These complexities may add anywhere from two to four weeks to the tool creation process. For instance, parts with simple parting lines may take two weeks to design, while parts with hand loaded inserts forming undercuts could take four weeks or more to design. These increased tool complexities can also increase the time required in the physical production of the tooling. The next step in creating a short run tool is choosing the die material. This choice affects the time to produce the die, the die life, and the cost of making the die. For shorter run tooling it is important that the material chosen matches the application. A general rule of thumb is the shorter the required life the less cost associated with and shorter time required in creating the tool. The cost of creating a tool is also dependent on the complexity and size of the tool. Once the die material is chosen, a rapid tooling method can be chosen to create the short run tool. A number of factors go into the choice of rapid tooling method. Often the overall size of the die insert eliminates some methods. Also, the required lead time can guide the choice. As one would expect shorter lead times increase the cost. Some die casters are utilizing rapid tooling methods as a regular part of their production plan to meet customer needs for short production runs. Many rapid tooling approaches work well for components in medical devices or aerospace parts with quantities below 50,000 pieces. In addition, companies often use universal tool holders with standardized casting insert pocket sizes and ejector plate systems for production efficiency. This approach may require some modifications of the part design to accommodate the limitations of the standard bases, or additional machining or drilling after casting. However, depending upon the part quantity and complexity, the cost of these extra steps will be offset by the reduced lead time and cost of the tool compared with a traditional die.

Short Run Tooling Process

To successfully produce a short run tool, the tool must be designed and created quickly. Also, the tool should last only as long as it is needed. This is because increasing the life of a tool increases the cost of the tool. Creating a short run tool begins with a solid CAD model that typically has the following qualities: Ample Draft Optimum radii and fillets Appropriate machine stock (if applicable) No surface or geometry errors Appropriate design considerations for wall thickness and thin tool steel conditions Once the CAD model is available, delivery of the parts for small production runs with machined dies depends on several key factors including the part/tool complexity, the die material, and the rapid tooling method used. 1

Die Material Choice

When creating short run tooling, it is important to select the die material that last for the required number of shots. Premium grade hot work tool steels cost much more than many other steels. These premium steels cost more both in the forming of the tool and also the price of the material. By using more economical steel the tool life may fall to less than 10,000 shots. However, the tooling costs and lead time will be significantly lower with these softer steels. If less than 10,000 shots are required, a premium grade tool capable of 100,000 shots is an unnecessary expense.

W H I T E Research conducted at Case Western Reserve University evaluated a multitude of die materials (Schwam, 2007). These materials were H-13, H-11, 4140, P20, high strength gray iron, and ductile iron.

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production have originated from defense applications, the North American Die Casting Association (NADCA) has been active in a number of rapid tooling research projects in conjunction with the Department of Defense (DOD), the Defense Logistics Agency (DLA) and several academic institutions. One of the outcomes of this effort is the development of the rapid tooling selection tool found on the NADCA website at www. diecasting.org/research/rapidtool. The Design Knowledgebase and Rapid Tooling Selection Tool assists designers in selecting the most appropriate rapid tooling method based on the lead time requirements and production volume. For low volume production of fewer than 1,000 pieces, there are 12 tooling methods with lead times ranging from seven days to 20 weeks. There are 10 methods that can be used for producing between 1,000 and 10,000 parts, and five tooling methods that can be used in dies suitable for more than 10,000 pieces but less than the 100,000 shots or more that would be possible with a traditional die. These different tool lives comes from the different materials utilized by each rapid tooling process.

Figure 1: Comparison of die lives for different die materials. In Figure 1 the measured crack areas are shown as a function of the number of shots is shown for many die materials. Larger crack areas indicated a deteriorating die nearing the end of its life. Note that all the materials tested will perform as needed up to 1000 shots. Further work has been done with 4140 steel at The Ohio State University (Miller, 2000). This case study evaluated the conversion of a machined base to a die casting. To reduce the cost of evaluating this conversion the tool was made from 4140. The surprising result was that the breakeven point for the tool occurred at 200 shots. The tool was used for 600 shots, and the author estimated another 500 could have been made with no major issues. This study illustrated how using this softer 4140 steel allowed a tool to be made quickly with low costs to satisfy the customer requirements. When more than 1000 shots are required, P20 is often used. This steel provides a good compromise between formability and tool life. Many die casters favor this material for short run production.

Within these various methods, there are two basic techniques either additive or subtractive. Additive methods, such as Direct Metal Deposition (DMD) or Selective Laser Sintering (SLS), create the tool by adding successive micrometer or millimeter-thick layers of material. The layers, which correspond to the virtual cross section from the CAD model, are glued together or fused to create the final shape. The primary advantage of additive construction is its ability to create almost any geometry. The subtractive method uses traditional machining, but substitutes H-13 or other pre-hardened steels for standard tool steels. Modern cutting tools allow machining of steels up to 40-42HRC, while eliminating heat treating after machining reduces lead time. Die life can extend from a few thousand shots to tens of thousands depending on the configuration of the part. In addition to evaluating the lead time and production quantity, factors affecting the selection of a rapid tooling method include the size and complexity of the part. The majority of rapid tooling methods are limited to die sizes of less than 10 inches, although the Direct Metal Deposition method can be used for dies of up to 41 x 78 x 24 inches. The layering of material in additive methods makes it more difficult to add certain features such as cooling fins or other standing metal elements in the finished product. 2

Rapid Tooling Selection

Often when tooling is needed for shorter runs, waiting for a long time to produce the tooling is not desired. This is why rapid tooling is essential to short run tooling in die casting. Since many of the requirements for low volume

W H I T E More details on specific types of rapid tooling methods, as well as an analysis of the factors affecting selection may be found in the NADCA White Paper Rapid Tooling Provides Production and Cost Advantages. The paper is available at www. diecastingdesign.org in the additional resources section.

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Example of Rapid Design to Production

A part developed by Twin Cities Die Casting (TCDC) and Mo-Tech illustrates the interrelationship of these various elements. Based on the CAD model received from the customer (Figure 2), Twin Cities provided Mo-Tech with a gated model on March 14. Mo-Tech designed inserts (Figure 3 to fit into TCDC 20 x 25 inch universal holder (Figure 4) on March 16. The inserts were machined from pre-hardened H-13 steel. The job timeline and steps involved to complete the inserts (Figure 3) are shown below: Model March 14 Design March 16 Ordered Steel March 16 Steel Programming March 16 Electrode Programming March 20 Received Steel March 21 Machining Steel March 22 Machining Electrodes March 25 Manual Machining March 20 to April 3 EDM March 27 Polishing April 3 Delivery April 4 Total time - 3 weeks Total hours (attended) 172 hrs. Total hours (unattended) 36 hrs. Figure 4: TCDC 20 x 25 inch universal holder block.

Figure 3: Inserts designed by Mo-Tech to fit the universal holder block.

Additional Advantages
While rapid tooling methods are increasingly being used for short or intermediate production runs, these techniques also are valuable as an interim step for larger production runs. Among the benefits are reducing testing time, adapting tools for multi-cavity production and decreasing lead time for production tools. For example, rapid tooling allows die casters to create parts that will have the same mechanical properties as a production tooled die cast part, thus reducing the number of necessary product tests. When prototypes are created using different methods than the production mode, multiple product tests may be required. Likewise, information about a part made with rapid tooling can be applied to the gating, overflow and venting designs of production tools, further reducing lead times for full-scale production. Finally, if designed properly, the rapid-tooled cavity inserts can be carried over and used in a multi-cavity production die casting die.

Ongoing NADCA Research

As part of the 2009 NADCA Research & Development Strategic Plan and Roadmap, two key projects related to rapid tooling are currently in progress. The intent of these 3

Figure 2: CAD model recieved from customer.

W H I T E activities is to produce and transfer results to the industry to assist with profitable growth, the ability for die castings to compete with other processes, and enhance the ability of die casters to compete in the domestic and global market. The first effort, Project #150: Computational Tool for Short Run Insert Production and Improved Yield, (A. Miller, The Ohio State University) is focused on developing a computational tool that will match insert configuration and with the appropriate die block. This would result in providing production ready tooling more quickly and assist in achieving first time success for short runs. Currently, there are no electronic tools to assist the die caster in determining which die casting inserts are the best match for readily available modular holder blocks. The second initiative, Project #151: Rapid Tooling for Short Run Metal Mold and Increased Productivity, (D. Schwam, Case Western Reserve University), builds on some of the previous research using rapid tooling methods to cast military components via a high integrity casting process. New rapid tooling methods, which may be identified, will be assessed for casting tooling viability. In addition, the utilization of high heat diffusivity alloy inserts and rapid tooling inserts with conformal cooling lines will be assessed for productivity gains.

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Works Cited
Miller, R. A. (2000, May/June). Short-run and Prototype Die Casting. Die Casting Engineer , pp. 24 - 28. Schwam, D. (2007). Rapid Tooling for Die Casting Dies. Metalcasting Congress. Transaction: T07-061 Houston Texas: NADCA.

About NADCA
Headquartered in Wheeling, IL, The North American Die Casting Association (NADCA) acts as the voice of the die casting industry, representing more than 3,100 individual and 300 corporate members in the United States, Canada and Mexico. NADCA serves the industry by providing industry news, technical information, networking opportunities, publications and trade events. NADCA is committed to promoting industry awareness, domestic growth in the global marketplace and member exposure.

Conclusion
Design, material selection, and rapid tooling advancements have increased the abilities of die casters to produce parts that would not be cost-effective using traditional dies. Designers can choose die casting not just because they are making hundreds of thousands of a particular part. Instead designers can utilize die castings tight tolerances, attractive surface finishes, and thin wall capabilities even for smaller quantities. Efforts by die casters, academic institutions and NADCA are continuing to expand the range of fast and economical applications of short run tooling techniques for everything from prototype development to production of relatively small quantities.

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