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Summary

The aluminum die casting enables to build precise products with high productivity in short cycle

even if the product shape is complicated and thin. However, a process of filling up the hot molten

metal speedily grows high load to the die, causing problems such as core pin breakage and mold

breakage, resulting into disturbance to the MP operation. In order to eliminate the pin breakage, the

engineers thoroughly investigated and analyzed the actual products on site and understood the

mechanism of the pin breakage due to seizure. Then the pin design standard was optimized using

Quality Engineering and adopted to the mass production. This improved the MP operation. Moreover,

by conducting design operation with the optimized standard, the MP preparation process without re-

designing was achieved.

Optimization of Die-Design Standard for Core Pin

1

2

Takashi O zeki Yusaku M urao

28

1

Fig.1

12 Pow ertrain Production E ngineering D ept.

Fig.1 Die-Casting

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2

A

Fe-A l-SiB

Fig.2C

D

E

Fig.3

3

Fig.4

Table 1

4

4.1

8

L18T able 2

4.2

Fig.2 Fe-Al-Si Compound Layer

Fig.3 Pin Breakage by Burning of Aluminum

Fig.4 Relation of Surface Area-Load

Table 1 Noise Factor

Table 2 Control Factor and Level

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Fig.5

5

5.1

Fig.6

A

B

L18

5.2

SN

T able 3

SN Table 4

Fig.78

5.3 Fig.78SN

Fig.5 Experimentation

Fig.6 Relation of Surface Area-Load

Table 3 Analyses Data

Table 4 S/N Ratio, Sensitivity Calculation Result

Fig.7 Response Graph S/N Ratio

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Table 5SN

6

6.1

Fig.9

E

6.2

Fig.78SN C

CE

D

6.3

650kgf3,000kgf

600kgf1,000kgf

Fig.10

L18

Fig.1112

Fig.8 Response Graph Sensitivity

Table 5 Confirmation Test Result

Fig.9 Test Result

Fig.10 Relation of Surface Area-Load

Fig.11 Response Graph S/N Ratio

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Fig.1112SN

Table 6

SN

SN 6db

1/4

CE

2db

30

7

78

50

V ol.15p.91-961999

Fig.12 Response Graph Sensitivity

Table 6 Confirmation Test Result