Shown is the tooling design outcome of a high pressure die cast tool with four hydraulic slides in a die orientation opti- mized based on multiple fl ow simulations.


late 2009, the car was not delivered to retail customers until late 2011. According to the U.S. Environ-


mental Protection Agency (EPA), the Karma’s range, with a full tank of gas and fully charged battery, is 230 miles. EPA rates its combined city and high- way fuel economy equivalent to 52 miles per gallon. T e car also includes a solar panel on its roof to assist in both climate control of the interior and charging its battery.


Why Die Casting A number of factors can ulti-


mately lead to the choice of a die casting. Production volume, how- ever, is key. The diecasting process offers the ability to produce higher quantities of parts per hour, which ultimately is more cost-effective. Cycle times with diecast compo-


nents can be greatly reduced, accord- ing to Olson. T e process also provides good near net shape and dimensional capability, potentially casting fea- tures that would otherwise have to be machined. In addition, machine stocks and wall thickness can be reduced, which reduces part weight and ma- chining cycle times. “T e big factor is cost,” Olson said.


“In cost savings, the raw casting might be half the cost or greater with high pressure diecasting (HPDC) than what it is as a sand casting, because we can make so many more an hour.” Tooling, however, is typically more


expensive when utilizing HPDC. T ough reduction comes in the piece cost, tooling costs will be higher. Dur- ing the design and sourcing decision


Nov/Dec 2012 | METAL CASTING DESIGN & PURCHASING | 35


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