Wallaceburg, Ontario Canada

Head Office/ Die Cast Facility and Design/ CNC / Plastic injection molding Facility
Wallaceburg, Ontario Canada
- AarKel Tool and Die Inc. (Main Office, MFG.)
- 110,000 sq. ft. total air conditioned operating space
-156 full-time employees
Global Capabilities
Sales / Program Management
Service
 24hr Global Access
 Start up Support
 Dedicated Team
One point of contact
 Quick quote turn around
Extensive knowledge and
multiple skill sets
Design & Engineering
 Full 3D Solid Design
 Feasibility
 Simulation/FMEA
 Multiple tool concepts
Quality Control
Dimensional reports
for tool and part
 Documentation
 Gauges & Fixtures
 GD&T
Tryout
 Internal & local tryout facilities for injection
molds under production conditions
 Pre production/Launch support
Prototyping
 Resin, aluminium
and steel tooling for
 Injection
 Compression
 Die Casting
Production Tooling
 Tool manufacture
 HSM Capabilities
 50 to 5,000 ton
 Repairs/ Engineering Changes
LOCAL CAPABILITIES
 Program Management
 Die Cast Die Manufacturing
Plastic Injection Tool Manufacturing
Prototype Tool Manufacturing
 Product Design
 Tool Design
 CNC / EDM Machining
Combining the skills and assets of our “Local Presence” and
our “Global Resources” we offer our customers a single point
of contact from which together, we can select from a complete
array of Product Development Services that are best suited
for the scope of your project requirements.
 Assembly & Inspection
 Part Tryouts & Production Runs
Your “Full Service” Partner
MACHINE CAPABILITIES…
5 axis High speed LARGE CNC
machines
EDM Sinker tanks with CNC graphite
machines
Gundrills with 5 axis gundrill/boring
mill
Welding department adjoined with
internal furnace for full process weld
requirements
Any Size, Any Shape,
Great Results…
DIE CAST DIES (500 to 4000 ton range)
 Ford & GM converter housings
 Magnesium Instrument panel dies
 Cast aluminum engine blocks
Oil pans
Low pressure & high pressure dies
Nissan ZV5 Consignment tooling
Any Size, Any Shape,
Great Results…
Engineering Manager
Die cast experience – 20 years
Die Cast Specialists
 Die cast experience – 29 years
 Engine Blocks – 4, 6 & 8 cyl,
including Northstar, transfer cases,
steering houses, transmission cases,
clutch housings, differential carriers,
cross car IP beams (largest
magnesium casting in the world) etc.
 Product and tool design expertise
Die Designers
5 Designers - Die cast experience – 20 years
10 years
10 years
10 years
7 years
Program managers
3 Managers - Die cast experience – 28 years
14 years
3 years
PROTOTYPE & ALUMINUM PRODUCTION
 Rapid prototypes – SLA /SLS
 Tooling fease & production phase
support
 Aluminum prototype tools
 Low volume aluminum production
w/ full actions
Any Size, Any Shape,
Great Results…
 6000 sq/ft manufacturing area with its own
dedicated personnel
 Has easy access to all AarKel departments
and capabilities.
 Fan Blades to Bumper Fascias
 Non-Automotive Parts
PART FEASIBILITY & MOLDING
ASSESSMENT
 Full Draft & Tooling Feasibility Studies
Draft analysis and mold ability studies have
proven to save valuable time and money.
With input from the tool manufacturer
early in the program, problem areas for
molding as well as molding methods can
be introduced for optimum tooling and
production requirements. This can have a
direct effect on piece price.
Any Size, Any Shape,
Great Results…
Engineering and Design…
Design functions are:
- Data management
- Feasibility study
- Part comparison
- Draft analysis
- Part warp
- Moldflow and Manifold
- Product design
- Mould design
SUPPORTED CAD SOFTWARE
CATIA V5
CADKEY/XMD
IGES
UNIGRAPHICS
IDEAS/SDRC
PARASOLID
CIMATRON
STEP
DXF/DWG
We Offer:
• Full product design and feasibility studies
• Complete internal tool making capabilities from
• 50 to 5000 ton tooling requirements
• 24/7 Program management support
• 24/7 Tooling support from cradle and beyond
program launch on ALL programs
• One stop tool shopping from
DESIGN > PROTOTYPE > PRODUCTION > LAUNCH
• Complete LCC tooling integration (each tool is
torn down and verified that all items are to customer
standards)
Die Casting Dies



Transmission housings
Magnesium IP’s
Cast aluminum engine blocks
Die Casting Dies
Specific specialty in 500 – 4000 Ton Range
Building Strong Relationships
- Toyota Engine Block Holders
- Replacement Cavity Inserts
- Toyota Case Transmission
- Honda Water Pump\
- Upper and Lower Valvebodies
- Nissan ZV5/ZV7 Engine Blocks
- Hyundai I-4 Engine blocks
replacement inserts
- Die modifications / repairs
- Jeep - Half I/P Steering Column Support
- JK Full Cross Car Beam Instrument Panels
- Y-Car Corvette Steering Column Support
- Ford Oil Pan
- PTU-Cover
-Valeo Mono-Block
- Front and rear case
- I-4 Engine Blocks
- V-6 Engine Blocks
- Transmission Cases
- Low Pressure Cylinder Head Dies
- Replacement inserts 100% certified
- 4T65 Channel Plates & Trans Case Dies
- 4T45-E Trans Case Dies
- 6T75 Six Speed Converter HSG & Trans
Case
- 6T40 Six Speed Converter HSG & Trans
Case
- 6L80-E RWD Transmission Dies
- 6L90-E RWD Transmission Dies
- Northstar Engine Block
- GF6 Case and Convertor (4 veriations)
- Rebuilds & Refurbishments
- Ford Rack & Pinion
- Ford U22 Carrier Axle
- Clutch Replacement Inserts
- BMW E60 Rear Cradle
- GMX-321 Rear Cradle
- Hyundai Front Cradle
-- GM Alpha Cradle
- R&D projects
- Front and Rear Transfer Case
- International Engine Covers
- Allison Valve body
- Cover
- Ford Rear die Case
- Volvo FWD Transmission Case
de Mexico
-Water Jackets
de Mexico
- Nissan AFO Case Auto Transmission
- Rotax - Cylinders die over mold
--Rorax – Case and Housing Die
- Full Cross Car Beam Instrument Panels
ENGINE BLOCK TOOLING
Experience
Concept & Design
Die Functionality
Die Flow & Analysis
Design Validation
Life Cycle &
Maintenance
Advanced
Quality Planning
We will
Deliver…
Concept & Design
SCOPE - to offer our customer an option to the traditional design style of oversized dies and
mechanisms which ultimately add to the manufacturing and operational costs of the program.
Advantages of the “Bank Core Design”
Improved Quality
- Improve dimensional stability of the cylinder locations
-Cooling control of the bank core assemblies
Aar-Kel “U.S. Patent” Design
BANK CORE MECHANISM
Improved Cycle Times
- Smaller die casting die and machine will cycle faster
- Improved cooling of the bank cores
Reduced Capital Equipment Cost
- Reduced die size utilizing “maximum material requirement”
(software)
- Reduced cost to purchase smaller tonnage DCM's
 Reduced Manufacturing Cost
- Smaller tools thus reduced cost to maintain
- Increased travel of the bank core
- Provides area for flash and debris to escape the cavity area
- Reduced cost to maintain bank shut-offs in the bank core
assembly area
- Size means less costly refurbishments and rebuilds
 Removal of Bank Core from within Machine
Noted on NADCA website: www.diecasting.org
Concept & Design
2500 Metric Ton Machine Specs
 Tie Bar Distance= 76” Horiz... x 80” Vert.
 Shot Position = 13.78”
 Tie Bar Dia.. = 13”
 Min. Die Height = 49”
 Max. Die Height = 72”
 Ejection Stroke = 9.8”
 Max. Daylight = 125.19”
Machine Calculations
Projected Area = 167 sq in + 50% (gates/overflows) = 250.5 sq in
15,000 PSI = 1878.75 Ton
10,000PSI = 1252.50 Ton
Concept & Design
Die Size and How it works:
68.90”
How Does the Bank Core Design Work?
70.00”
66.00”
The “bank side core assembly” is made up of two racks, bank core carrier,
bank core inserts, pinion and a hydraulic motor or hydraulic driven rack which is
mounted on the side of the ejector holder block.
The concept is to have pancake cylinders do the initial movement by pushing
on the back core carrier, stripping the bank core from the cavity. The pancake
cylinders are screwed to the ejector holder block allowing easier access for
plumbing. Once the pancake cylinders have moved the hydraulic motor or a
hydraulic driven rack system will then move the complete bank core assembly
away from the cavity. The hydraulic motor is connected to a pinion that goes
thru the ejector holder and two rack units that are connected to the bank core
carrier allowing the complete bank core unit to be pulled away from the cavity.
Once the bank core has been moved away this will then allow any debris to be
removed from the die thru a hole that is in the ejector holder. This hole would be
big enough to allow flash to exit to the outside of the die. The addition of a blow
nozzle would assist in the removal of any debris.
Once the cycle has been completed the hydraulic motor will move the bank
core assembly back into the forward position. The bank core locking plate
would then close up holding all of the injection pressure for the next shot.
Concept & Design
BANK CORE CONCEPT
Click image to view anmated file of die section…
Click screen to view animated file of die sequence…
Functionality
Die Flow and Analysis
Following is a preliminary
simulation to get an
impression about the casting
solidification pattern and
cavity filling conditions.
Pouring temperature - 650C / 1202F
Die temperature to 150C / 300F
Filling and solidification is calculated
in the 1st cycle.
Cavity filling time = 120 msec.
Cooling / heating lines are not introduced
Venting was not included in this simulation
Liners are not included at this time.
Die Flow and Analysis
Die Flow and Analysis
Filling by Temperature
Die Flow and Analysis
Porosity due to Solidification
Colored locations
solidify later than the
areas around them.
Porosity could be
developed here.
Cooling lines should
be placed close, to
reduce porosity and
increase productivity.
Die Flow and Analysis
CAE - Driven Mold Design and Engineering
GIFU DIE & MOLD ENGINEERING CO.,LTD
F.E.A. analysis on Bank Core
components
Stress
Heat
Solidification
Filling
Die Temperature
Cyclic Cooling Mold Filling
Deformation
Maximum Material Utilization
 Reduction of holder block sizes
 Improved of cycle times
 Reduced size requirement for D.C.M.
 More even die temperatures
 Reduced tooling cost
Design Validation
CAE – Total Displacement
disp.
Y:0.62
COVER HOLDER
disp.
X:0.72
disp. X:0.72
@15,000 psi
Large displacement is calculated.
We recommend reinforcing the
cover die by increasing its XY
dimensions.
disp.
Y:-0.51
disp.
Z:0.26
Design Validation
CAE – Total Displacement
EJECTOR HOLDER
0.64
0.29
@15,000 psi
0.17
Design Validation
CAE – Total Displacement
EJECTOR DIE BASE
0.19
0.17
0.19
0.18
@15,000 psi
Bottom view
Design Validation
CAE – Total Displacement
Displacement of Bank Core along the Sliding Direction
(mm)
@15,000 psi
0.61 (.024”)
direction
Step of 0.39mm will appear
Bank Core : 0.61
0.18
Block : 0.22
Oper. bank
(.007”)
The amount of transformation by
compression : 0.43mm
※The amount of inevitable transformation by compression is
calculated to be 0.43mm
Bank’s total length 840mm x Cavity pressure103.43MPa
≒ 0.43mm
(.017”)
Young’s modulus 200GPa
Section view
Overview
We believe Aar-Kel tool and Die Inc. represents the best combination of
value and capability in the die cast tooling industry today.
At Aar-Kel we can provide an unparalleled combination of technical skills
and manufacturing capabilities. Furthermore, by utilizing proven business
partners in lower labor cost countries, we offer customers lower costs
while minimizing the risks.
Let us prove to you why our capabilities and resources are what today's
leading automotive suppliers are looking for in their “full service”
product development partner.
President :
Larry Delaey
519. 358.5830
CFO :
Mary VanSantvoort
905 .978.2821
Business Development Manager:
Kevin Van Damme
519. 360.7702
Business Development Manager:
Andrew Stewart
519. 359.7743
Business Development Manager:
Andrew Spittal
519. 365.4548
Thank you!