Godrej Tooling, Mumbai, India, entered the automotive segment 15 years ago as a high pressure die casting toolmaker for what is known in India as the 2-wheeler (motorcycle) industry. However, in the recent past the large number of series production dies needed by the 2-wheeler industry has provided an ideal learning platform for new die makers, resulting in many new companies entering the field.
In order to create a new market for itself, Godrej Tooling decided to address the need for larger die cast-ing dies for automotive applications. The dies for transmission and engine components are large and complex and, being comparatively low in vol-ume, may result in only one die being produced in a year. Successful designs require intense upfront engineering work to ensure that critical areas are properly addressed. The strategy of building up the infrastructure and the design competency for large dies prior to entering into the market worked well for Godrej Tooling. It helped to ensure success on early orders and earned them a positive reputation in the automotive market for large dies.
The following case study of one of the early orders showcases the evolution of the design process from the first iteration to the final layout. The entire activity was completed in a crucial two week period of die development, and it ultimately yielded results of 98% of parts meeting the customer‘s acceptability standards on the first test run.
Upon the receipt of the inquiry, an initial solidification analysis was done to verify the castability of the part design and to identify the basic quality issues. In this way, simulation supported the designer at the earliest possible stage, before the design was fixed and while changes could still be incorporated.