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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