{"id":4739,"date":"2019-11-08T09:37:25","date_gmt":"2019-11-08T08:37:25","guid":{"rendered":"https:\/\/www.studiodsm.com\/project\/stampo-deckler-cover\/"},"modified":"2020-10-27T08:50:48","modified_gmt":"2020-10-27T07:50:48","slug":"deckler-cover-mould","status":"publish","type":"dt_portfolio","link":"https:\/\/www.studiodsm.com\/en\/project\/deckler-cover-mould\/","title":{"rendered":"Deckler Cover Mould"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><p>[vc_row equal_height=&#8221;yes&#8221; type=&#8221;vc_default&#8221; css=&#8221;.vc_custom_1575291876546{margin-bottom: -70px !important;}&#8221;][vc_column width=&#8221;1\/2&#8243; css=&#8221;.vc_custom_1575291908923{padding-bottom: 50px !important;}&#8221; offset=&#8221;vc_col-lg-4 vc_col-md-5&#8243;]<div id=\"ultimate-heading-34886a0d4eed9f7f1\" class=\"uvc-heading ult-adjust-bottom-margin ultimate-heading-34886a0d4eed9f7f1 uvc-9984 \" data-hspacer=\"no_spacer\"  data-halign=\"left\" style=\"text-align:left\"><div class=\"uvc-heading-spacer no_spacer\" style=\"top\"><\/div><div class=\"uvc-main-heading ult-responsive\"  data-ultimate-target='.uvc-heading.ultimate-heading-34886a0d4eed9f7f1 p'  data-responsive-json-new='{\"font-size\":\"desktop:30px;\",\"line-height\":\"desktop:30px;\"}' ><p style=\"--font-weight:theme;color:#333333;margin-bottom:30px;\">DECKLER COVER MOULD<\/p><\/div><div class=\"uvc-sub-heading ult-responsive\"  data-ultimate-target='.uvc-heading.ultimate-heading-34886a0d4eed9f7f1 .uvc-sub-heading '  data-responsive-json-new='{\"font-size\":\"desktop:20px;\",\"line-height\":\"desktop:25px;\"}'  style=\"font-weight:normal;\"><\/p>\n<p align=\"JUSTIFY\"><span lang=\"en-GB\">CASTING STUDY,<br \/>\nSIMULATION AND DESIGN<\/span><\/p>\n<p><\/div><\/div>[vc_empty_space][vc_column_text css=&#8221;.vc_custom_1603178767512{margin-bottom: 40px !important;border-left-width: 3px !important;padding-left: 20px !important;border-left-color: rgba(0,0,0,0.1) !important;border-left-style: solid !important;}&#8221;]<strong><span class=\"color-secondary\"><span style=\"color: #333333;\">Objective: <\/span><\/span><\/strong>Industrialisation of a structural component that is required to have good oil seal properties for application in the automotive sector<\/p>\n<p><strong><span class=\"color-secondary\"><span style=\"color: #333333;\">Process: <\/span><\/span><\/strong>Die-casting technique; alloy used: Alsi9Cu3 (UNI EN AB 46000)<\/p>\n<p><span style=\"color: #333333;\"><strong>Requirements: <\/strong><\/span>Design a mould with at least 2 cavities; avoid porosity in a well-defined heavy section to be subjected to mechanical processing<\/p>\n<p><span style=\"color: #333333;\"><strong>Results: <\/strong><\/span>Guaranteed component integrity; 4-cavity mould with significant reduction of operating costs<\/p>\n<p><span style=\"color: #333333;\"><strong>Client: <\/strong><\/span>Magna, in cooperation with Galba s.r.l and Alpress s.r.l.[\/vc_column_text]<style type=\"text\/css\" data-type=\"the7_shortcodes-inline-css\">#default-btn-e536f33bb6d56e3c78544426c6bccb35 {\n  border-radius: 4px;\n  font-size: 14px;\n  line-height: 16px;\n}\n.btn-shadow#default-btn-e536f33bb6d56e3c78544426c6bccb35 {\n  box-shadow: 0 1px 6px rgba(0,0,0,0.12);\n  transition: box-shadow 0.2s ease-out, opacity 0.45s;\n}\n.btn-shadow#default-btn-e536f33bb6d56e3c78544426c6bccb35:hover {\n  box-shadow: 0 5px 11px 0 rgba(0,0,0,0.18), 0 4px 15px 0 rgba(0,0,0,0.15);\n}\n.btn-3d#default-btn-e536f33bb6d56e3c78544426c6bccb35 {\n  box-shadow: 0px 2px 0px 0px #265279;\n}\n.btn-3d#default-btn-e536f33bb6d56e3c78544426c6bccb35:hover {\n  box-shadow: 0px 2px 0px 0px #265279;\n}\n.btn-flat#default-btn-e536f33bb6d56e3c78544426c6bccb35 {\n  box-shadow: none;\n}\n.btn-flat#default-btn-e536f33bb6d56e3c78544426c6bccb35:hover {\n  box-shadow: none;\n}\n#default-btn-e536f33bb6d56e3c78544426c6bccb35.ico-right-side > i {\n  margin-right: 0px;\n  margin-left: 8px;\n}\n#default-btn-e536f33bb6d56e3c78544426c6bccb35 > i {\n  margin-right: 8px;\n  font-size: 12px;\n}\n#default-btn-e536f33bb6d56e3c78544426c6bccb35:not(:hover) {\n  border-width: 0px;\n  background: #1e73be !important;\n  padding: 12px 18px 12px 18px;\n}\n#default-btn-e536f33bb6d56e3c78544426c6bccb35:hover {\n  border-width: 0px;\n  background: #1e73be !important;\n  padding: 12px 18px 12px 18px;\n}\n#default-btn-e536f33bb6d56e3c78544426c6bccb35.ico-right-side > i {\n  margin-right: 0px;\n  margin-left: 8px;\n}\n#default-btn-e536f33bb6d56e3c78544426c6bccb35 > i {\n  margin-right: 8px;\n}<\/style><a href=\"https:\/\/www.magna.com\" class=\"default-btn-shortcode dt-btn link-hover-off btn-inline-left btn-flat \" id=\"default-btn-e536f33bb6d56e3c78544426c6bccb35\" title=\"Magna\"><span>Web site<\/span><\/a>[\/vc_column][vc_column width=&#8221;1\/2&#8243; css=&#8221;.vc_custom_1575291917463{padding-bottom: 50px !important;}&#8221; offset=&#8221;vc_col-lg-8 vc_col-md-7&#8243;][vc_column_text css=&#8221;.vc_custom_1603178902718{padding-bottom: 30px !important;}&#8221;]<span style=\"color: #333333;\"><strong>The action<\/strong><\/span><\/p>\n<p>To identify the most performing solution, we assessed various possibilities.<br \/>\nFirst, we set aside the idea of simulating a casting sprue by using the lower part of the piece because the Material Trace data indicated that the two runners did not work properly and resulted in non-homogeneous mould filling with material that tended to detach itself. Thanks to Hot Spot we identified the criticality of hot spots that formed due to the molten metal\u2019s incapacity to occupy the entire volume once solidified. The positioning of a squeeze pin close to the heavy section could have solved the problem, but the presence of trapped air would have limited its benefits. We then decided to study a targeted casting on the part\u2019s heavy section so as to reduce to a minimum the shrinkage porosity and reduce entrapped air. To do this, we had to add another insert mechanism and so, in order to lower operating costs, we decided to add 2 profiles while choosing to use a 4-cavity mould.<br \/>\nThe simulation with Material Trace showed that with this casting solution the melt was \u201caccompanied\u201d evenly. Air Pressure data showed that the new layout brought air outside the part so as to be vented. Porosity showed substantial reduction in porosity. Based on the results of the simulation, we positioned a chill vent in the area that filled last with the molten metal, thereby drastically reducing the residual air inside the die, as also confirmed by the MAGMA 5 data. At that point, we designed the 3D version of the mould with its heat regulation circuits, designed with the aim of keeping a not too high temperature so as to reduce cycle time. We then simulated 9 cycles to make sure the heat range of the mould stayed around 200\u00b0C.[\/vc_column_text][vc_column_text css=&#8221;.vc_custom_1603179000213{padding-top: 20px !important;padding-bottom: 35px !important;}&#8221;]<span style=\"color: #333333;\"><b>Results:<\/b><\/span><\/p>\n<p>Thanks to the solutions adopted, the porosity value was lowered significantly. It was fundamental to add a gate with an additional mechanism to work better on the third phase of the press. The cost of the mould was counterbalanced by the savings obtained by adding two additional profiles. The client\u2019s requirements were therefore met:<\/p>\n<ul>\n<li><span style=\"color: #333333;\"><strong>the component\u2019s integrity in the critical area was ensured<\/strong><\/span><\/li>\n<li><span style=\"color: #333333;\"><strong>a mould of 4, not 2, cavities was obtained, with considerable savings in operating costs.<\/strong><\/span><\/li>\n<\/ul>\n<p>[\/vc_column_text][vc_empty_space height=&#8221;70px&#8221;][\/vc_column][\/vc_row][vc_row equal_height=&#8221;yes&#8221; type=&#8221;vc_default&#8221; css=&#8221;.vc_custom_1575291876546{margin-bottom: -70px !important;}&#8221;][vc_column offset=&#8221;vc_col-lg-offset-0 vc_col-lg-12 vc_col-md-offset-0 vc_col-md-12 vc_col-sm-offset-0&#8243; css=&#8221;.vc_custom_1575292213114{padding-bottom: 60px !important;}&#8221;]<style type=\"text\/css\" data-type=\"the7_shortcodes-inline-css\">.gallery-shortcode.gallery-masonry-shortcode-id-b4a28f48640e6f9048b34ce53ddb8130 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data-post-limit=\"-1\" data-pagination-mode=\"none\" data-desktop-columns-num=\"4\" data-v-tablet-columns-num=\"4\" data-h-tablet-columns-num=\"4\" data-phone-columns-num=\"2\" data-width=\"0px\" data-columns=\"0\"><div class=\"iso-container\" ><div class=\"wf-cell iso-item\" data-post-id=\"4599\" data-date=\"2020-06-30T15:27:17+02:00\" data-name=\"Progetto Deckler Cover\"><figure class=\"post visible\"><a href=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler01.jpg\" class=\"rollover dt-pswp-item layzr-bg\" data-large_image_width=\"1080\" data-large_image_height=\"1080\" data-dt-img-description=\"\" title=\"Progetto Deckler Cover\"><img fetchpriority=\"high\" decoding=\"async\" class=\"preload-me iso-lazy-load aspect\" src=\"data:image\/svg+xml,%3Csvg%20xmlns%3D&#39;http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg&#39;%20viewBox%3D&#39;0%200%20369%20369&#39;%2F%3E\" data-src=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler01-369x369.jpg\" data-srcset=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler01-369x369.jpg 369w, https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler01-554x554.jpg 554w\" loading=\"eager\" style=\"--ratio: 369 \/ 369\" sizes=\"(max-width: 369px) 100vw, 369px\" alt=\"\" width=\"369\" height=\"369\"  \/><span class=\"gallery-rollover\"><span class=\"gallery-zoom-ico icomoon-the7-font-the7-expand-04\"><span><\/span><\/span><\/span><\/a><\/figure><\/div><div class=\"wf-cell iso-item\" data-post-id=\"4600\" data-date=\"2020-06-30T15:27:18+02:00\" data-name=\"Progetto Deckler Cover\"><figure class=\"post visible\"><a href=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler02.jpg\" class=\"rollover dt-pswp-item layzr-bg\" data-large_image_width=\"1080\" data-large_image_height=\"1080\" data-dt-img-description=\"\" title=\"Progetto Deckler Cover\"><img decoding=\"async\" class=\"preload-me iso-lazy-load aspect\" src=\"data:image\/svg+xml,%3Csvg%20xmlns%3D&#39;http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg&#39;%20viewBox%3D&#39;0%200%20369%20369&#39;%2F%3E\" data-src=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler02-369x369.jpg\" data-srcset=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler02-369x369.jpg 369w, https:\/\/www.studiodsm.com\/wp-content\/uploads\/2020\/06\/ProgettoDecler02-554x554.jpg 554w\" loading=\"eager\" style=\"--ratio: 369 \/ 369\" sizes=\"(max-width: 369px) 100vw, 369px\" alt=\"\" width=\"369\" height=\"369\"  \/><span class=\"gallery-rollover\"><span class=\"gallery-zoom-ico icomoon-the7-font-the7-expand-04\"><span><\/span><\/span><\/span><\/a><\/figure><\/div><div class=\"wf-cell iso-item\" data-post-id=\"4603\" data-date=\"2020-06-30T15:41:13+02:00\" data-name=\"Progetto Deckler Cover\"><figure class=\"post visible\"><a href=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2019\/11\/ProgettoDecler05.jpg\" class=\"rollover 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data-date=\"2020-06-30T15:41:11+02:00\" data-name=\"Progetto Deckler Cover\"><figure class=\"post visible\"><a href=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2019\/11\/ProgettoDecler06.jpg\" class=\"rollover dt-pswp-item layzr-bg\" data-large_image_width=\"1080\" data-large_image_height=\"1080\" data-dt-img-description=\"\" title=\"Progetto Deckler Cover\"><img decoding=\"async\" class=\"preload-me iso-lazy-load aspect\" src=\"data:image\/svg+xml,%3Csvg%20xmlns%3D&#39;http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg&#39;%20viewBox%3D&#39;0%200%20369%20369&#39;%2F%3E\" data-src=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2019\/11\/ProgettoDecler06-369x369.jpg\" data-srcset=\"https:\/\/www.studiodsm.com\/wp-content\/uploads\/2019\/11\/ProgettoDecler06-369x369.jpg 369w, https:\/\/www.studiodsm.com\/wp-content\/uploads\/2019\/11\/ProgettoDecler06-554x554.jpg 554w\" loading=\"eager\" style=\"--ratio: 369 \/ 369\" sizes=\"(max-width: 369px) 100vw, 369px\" alt=\"\" width=\"369\" height=\"369\"  \/><span class=\"gallery-rollover\"><span class=\"gallery-zoom-ico icomoon-the7-font-the7-expand-04\"><span><\/span><\/span><\/span><\/a><\/figure><\/div><\/div><!-- iso-container|iso-grid --><\/div>[\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>Casting study, simulation and design<\/p>\n","protected":false},"author":2,"featured_media":4611,"comment_status":"closed","ping_status":"closed","template":"","dt_portfolio_category":[],"dt_portfolio_tags":[],"class_list":["post-4739","dt_portfolio","type-dt_portfolio","status-publish","has-post-thumbnail","hentry","description-off"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Deckler Cover Mould - STUDIO DSM<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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