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In 2007, Milwaukee Electric Tool Corporation, located in Wisconsin, planned to launch a new miter saw. A high pressure die casting company was found to cast the saw base. A die was designed and built based on the die caster’s past experience. The first die trials produced visually sound castings and the results at the start of production were promising. This changed quickly during machining of the first parts delivered. Small amounts of air were entrapped and tiny porosities could be seen after machining. This was not an issue in terms of the functionality of the heavy duty saw, but a significant issue for the high quality standards Milwaukee Electric Tool Corporation stands for. Having the die built and the design set, the die caster did not have much room to improve the situation. In trials at the die casting machine, gates and runner branches were welded closed then grinded open again later on, process parameters were changed and overflows added, but the problems remained. The launch of the new miter saw was at risk. The decision was made to simulate the main changes to the die and to compare them with the defect images to get a better understanding about the causes of the air entrapment. First simulations immediately matched the real-world results, and a design of experiments could be developed. Changes of the runner and venting system, as well as process parameter variations were defined. Using the optimization module available with MAGMASOFT®, various simulations were autonomously performed without further input of the engineering group. After only two days, the software determined a die design that could be implemented easily, immediately and on a small budget. The production of the castings, using the new mould design and process parameter set, led to a scrap rate after machining that was negligible. The new saw was launched as planned, and with high level of quality that Milwaukee Electric Tool Corporation demands. Milwaukee Electric Tool Corporation is an industry leading manufacturer and marketer of heavy-duty, portable electric power tools and accessories for professional users worldwide. R. Kind, Ke Roth, Magma Foundry Technologies, Inc, Schaumburg, IL, Phone: 847-969-1001, Web: www.magmasoft.com
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