Wallaceburg, Ontario Canada - AarKel Tool and Die Inc. (Main Office, MFG.)

- 110,000 sq. ft. total air conditioned operating space

-156 full-time employees

Head Office/ Die Cast Facility and Design/ CNC / Plastic injection molding Facility

Global Capabilities

Service 24hr Global Access

Start up Support

Dedicated Team

Sales / Program Management 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

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

Tryout Internal & local tryout facilities for injection

molds under production conditions

Pre production/Launch support

Quality Control Dimensional reports

for tool and part

Documentation

Gauges & Fixtures

GD&T

LOCAL CAPABILITIES

Program Management

Die Cast Die Manufacturing

Plastic Injection Tool Manufacturing

Prototype Tool Manufacturing

Product Design

Tool Design

CNC / EDM Machining

Assembly & Inspection

Part Tryouts & Production Runs

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.

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

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

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…

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.

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 UNIGRAPHICS CIMATRON CADKEY/XMD IDEAS/SDRC STEP IGES PARASOLID DXF/DWG

Any Size, Any Shape,

Great Results…

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

Specific specialty in 500 – 4000 Ton Range

Die Casting 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

- Jeep - Half I/P Steering Column Support

- JK Full Cross Car Beam Instrument Panels

- Y-Car Corvette Steering Column Support

- Ford Oil Pan

- I-4 Engine Blocks

- V-6 Engine Blocks

- Transmission Cases

- Low Pressure Cylinder Head Dies

- Toyota Engine Block Holders

- Replacement Cavity Inserts

- Toyota Case Transmission

- Honda Water Pump\

- Upper and Lower Valvebodies

-Valeo Mono-Block

- Front and rear case

- 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

- Nissan ZV5/ZV7 Engine Blocks

- Hyundai I-4 Engine blocks

replacement inserts

- Die modifications / repairs

- Rotax - Cylinders die over mold

--Rorax – Case and Housing Die

- Ford Rear die Case

- Volvo FWD Transmission Case

- Full Cross Car Beam Instrument Panels

Building Strong Relationships

-Water Jackets

de Mexico

- Ford Rack & Pinion

- Ford U22 Carrier Axle

- PTU-Cover

- Nissan AFO Case Auto Transmission

de Mexico

- Clutch Replacement Inserts

Die Flow & Analysis

Die Functionality

Concept & Design

Experience

Design Validation

Life Cycle &

Maintenance

Advanced

Quality Planning

We will

Deliver…

ENGINE BLOCK TOOLING

Aar-Kel “U.S. Patent” Design

BANK CORE MECHANISM

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.

Noted on NADCA website: www.diecasting.org

Advantages of the “Bank Core Design”

Improved Quality - Improve dimensional stability of the cylinder locations

-Cooling control of the bank core assemblies 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

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

Die Size and How it works:

66.00”

68.90”

How Does the Bank Core Design Work? 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.

70.00”

Concept & Design

Concept & Design

BANK CORE CONCEPT

Click image to view anmated file of die section…

Functionality

Click screen to view animated file of die sequence…

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

Filling by Temperature

Die Flow and Analysis

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

Reduction of holder block sizes

Improved of cycle times

Reduced size requirement for D.C.M.

More even die temperatures

Reduced tooling cost

Maximum Material Utilization

Design Validation

CAE – Total Displacement

disp.

Z:0.26

disp. X:-

0.72

disp.

X:0.72

disp.

Y:0.62

disp.

Y:-0.51

@15,000 psi

Large displacement is calculated.

We recommend reinforcing the

cover die by increasing its XY

dimensions.

COVER HOLDER

Design Validation

EJECTOR HOLDER

0.64 0.29

0.17

@15,000 psi

CAE – Total Displacement

EJECTOR DIE BASE

0.19 0.17 0.18 0.19

Bottom view

@15,000 psi

Design Validation

CAE – Total Displacement

Displacement of Bank Core along the Sliding Direction

(mm)

Section view

Bank Core : 0.61 Block : 0.22

Step of 0.39mm will appear

※The amount of inevitable transformation by compression is

calculated to be 0.43mm

Bank’s total length 840mm x

Young’s modulus 200GPa

Cavity pressure103.43MPa

≒ 0.43mm

direction

0.61

0.18 Oper. bank

The amount of transformation by

compression : 0.43mm

@15,000 psi

(.017”)

(.024”)

(.007”)

Design Validation

CAE – Total Displacement

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.

Thank you!

Business Development Manager:

Andrew Stewart

519. 359.7743

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 Spittal

519. 365.4548