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CWM Capabilities
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Latest News from CWM
CWM News Archive
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Magmasoft® Simulation Avoids a Horror Story
Since CWM put the advanced Magmasoft software simulation system to work, its accurate thermal and metal-flow predictions prior to tooling design and prototyping have helped achieve first-piece production success with some especially challenging die cast part designs.
A recent project was a particularly dramatic example of the prevention of what could have been a tooling and production horror story. The product designers had developed what they believed was an excellent design for a successful die casting and were anxious to proceed. CWM engineers were wary of complete die cavity filling for certain part features and recommended a detailed Magmasoft simulation. Before proceeding with tooling design, the analysis was performed using the customer's CAD data. Results of the simulation modeling not only confirmed CWM's suspicions, but demonstrated that the original part design would have resulted in production dies incapable of being modified for successful production.
Component design changes recommended were agreed to and new flow simulations were run. The final production part met all customer requirements.
To download a PDF Tech Brief on the operation and benefits of the Magmasoft system for die casting, click CWM_Brief#23, "Magmasoft Process Simulation" in the Application/Tech Brief section of CWM's OEM Resource Center on this website, with over 60 free design guides & aids. To go directly to the Resource Center, click: Entry Page.
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New Machining Centers Expand CNC Capacity
The expansion of precision machining capacity with the installation of two Leadwell MV- 40 CNC Machining Centers was announced by Brian Andrews, V.P., CWM CNC Machining Division.
With 12,000 RPM spindles and 1280 IPM operation, these advanced new units offer greater scheduling flexibility at higher machining speeds and precision. Larger table sizes and machine travel allows CWM to combine multiple operations: jobs previously requiring three machine setups can now be completed in a single setup. Larger castings can now be machined in house, as well as a range of other larger-sized component designs.
Recent introduction of a CWM-developed subplate system for CNC machines has also resulted in significantly reduced setup times. CWM can now offer its precision machining customers faster turn-around times.
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Eric Treiber Chairs NADCA Govt. Affairs
Eric Treiber, President and COO of CWM, has been named Chairman of the North American Die Casting Association's Government Affairs Committee, it was announced by Dan Twarog, President of NADCA.
Fostering Alliances for the Industry
This Committee, on behalf of the entire die casting industry, is charged with aiding the fostering of strategic alliances with legislators in Washington and increasing the effectiveness of grassroots efforts of industry companies in helping achieve a positive legislative agenda. Its current program is focussed on the importance of retaining a strong, competitive manufacturing base in the U.S.
Eric brings to his chairmanship a background in helping develop industry-wide relationships with the U.S. EPA, which included participation in the agency’s Sustainable Industries Metalcasting Sector Program, plus the SF6 Emission Reduction Partnership for the Magnesium Industry.
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New QA Planning Mgr. Position at CWM
Sylvia Garcia has been appointed to the new position of CWM's QA Planning Manager, it was announced by Bill Baraglia, VP, Manufacturing. She will be responsible for establishing all dimensional appraisal procedures for die castings and related components.
The goal of this new position is to provide more timely feedback to further improve product quality and reliability. Sylvia brings significant experience to the new function, including 14 years in all quality departments of a major auto parts stamping company.
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As a Green Biz Co. CWM Leads its Industry
Based on its environmental leadership practices and participation in the EPA's National Environmental Performance Track program, Chicago White Metal Casting has been recognized as a GreenBiz Leader company, the first and, we believe, still the only custom die casting facility so named by the U.S. Environmental Protection Agency.
This EPA's programs recognize and encourage top environmental performers— those who go beyond compliance with regulatory requirements to attain levels of environmental performance and management that benefit people, communities, and the environment.
CWM's GreenBiz Leader recognition is the latest in a series of environmental initiatives and achievements leading its industry:
 1st to achieve ISO 14001 Certification
1st participant in EPA's Performance Track Program
Member of EPA's Sustainable Industries Partnership
And, of course, producer of Recyclable Products form Recyclable Alloys.
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Chicago Rehabilitation Institute Award to CWM
By implementing a plan to help an employee transition back into the working world after a stroke, Chicago White Metal has earned the 2007 Corporate Award from the prestigious Rehabilitation Institute of Chicago, which is dedicated to helping people with physical disabilities live a fulfilling life.
"CWM needed to work closely with the employee's rehabilitation case worker to review, organize and monitor his work schedules, workload and overall physical condition," according to Anne Andrews, newly appointed CWM Human Resources Manager. "We did this with the guidance of his direct supervisor and the managers of several CWM departments to determine what the optimum permanent fit would be for him at Chicago White Metal Casting."
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500% Cost Saving: Die Cast vs Machined Brass
The low-volume production of a small precision component for a medical device, produced in CNC machined brass, was put through value analysis against possible alternative production efficiencies. Results of the review indicated that a CWM net-shape 4-slide miniature zinc die casting could replace the machined part with no sacrifice in mechanical properties, at a significant cost reduction. The precision component is now being die cast at a 500% unit cost saving.
To download a PDF of the full case study of this part, click here for Miniature Die Casting Case Study No. 39 on the Case Study page in the OEM Resource Center section.
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China's CDMIA Issues Caution on Die Tooling
In a candid statement from the China Die and Mold Industry Assn. (CDMIA), its director stated that state ownership suffers a deficient system for producing sophisticated die casting dies and plastic molds based on inadequate numbers of qualified professionals.
According to the association's year-end report, quoted in Design News, one of the biggest problems plaguing Chinese mold making is lack of skilled workers. It states China's tooling industry remains substandard and largely incapable of making highly complex tools. Exported tools are termed mostly medium- or low-grade. A clear note of caution to U.S. OEMs.
For more on CWM capabilities, see this website's Capabilities Section, and click on "How CWM makes the highest quality die cast part at the lowest unit cost."
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New Primer on Miiniature Die Casting Released
New CWM Engineering Bulletin No. 76 provides OEMs with a condensed overview on how Miniature Zn & ZA-8 high-speed die casting process is the most cost-effective technology for small, complex structural parts.
This bulletin outlines the essential facts design engineers and purchasers should know about today's specialized machines, the types of component parts that qualify, the part design guidelines the process requires be followed, and cost and lead-time considerations.
To go directly to the OEM Resource Center's "Engineering Bulletin" section to download this new Bulletin, click here.
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New Mag Option for Chrome-Plated Plastic
The superior mechanical qualities of magnesium can now be combined with a premium cosmetic plated finish offering product designers a cost-effective new option. New joint material and process finishing developments have brought quality electroplating to Mg die casting for a wide range of new applications.
The new mag chrome-plated surface finishes for die cast housings and components are comparable to that achievable in high-quality zinc parts and superior to that of molded plastic.
Quality chrome plating for thin-wall, lightweight mag has long been a goal when an alternative to a painted surface was desired. Chicago White Metal Casting can now offer mag’s superior advantages in rigidity, impact strength and dent resistance with a premium-plated finish, at part weights comparable to plastic. Excellent heat dissipation and built-in EMI/RFI shielding are added benefits of Mg. The costly inserts often required for plastic parts can be eliminated.
For more on how this new Mag Alloy and Chrome Electroplating development could benefit your product planning, Email the CWM Sales Dept. or call 630-595-4424.
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Ultra-Rugged Specs Met by Hi-Tech Mg Housing
The new GR-3 GPS satellite tracking unit from Topcon Positioning Systems is a major breakthrough in technology.
Project managers at Topcon wanted the GR-3 enclosure to be as advanced as the technology inside: ultra rugged and durable but lightweight for portable field use; waterproof; dustproof, with fail-safe EMI shielding. A high-tech CWM hot-chamber magnesium die casting was the clear housing choice-- shock rated to survive 6.5 t. pole drops to concrete.
To examine full design and production details on this outstanding enclosure, click here for more on the PDF (CWM Case Study #38) in the Case Study section of the OEM Resource Center.
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Lean Manufacturing Practices to the Next Level
As part of its program of aggressively pursuing best lean practices, CWM has formalized lean manufacturing in its production procedures, incorporating continuing in-house training.
The CWM program is based on in depth reviews of the successful lean programs of its largest customers, with successful backgrounds in the formal application of lean manufacturing principles. CWM team members participated in comprehensive lean training sessions incorporating Kaisan events and Value Stream Mapping.
The lean manufacturing program at CWM has demonstrated its continuing effectiveness in revealing improvement opportunities.
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EPA-Compliant Chromate for Al, Mg & Zn Parts
Environmentally friendly trivalent chromium is now a proven, economical alternative to hexavalent chromium coatings, offering high corrosion resistance for CWM Al, Mg and Zn die castings in a range of applications.
With a bright, cosmetically pleasing finish, this alternative combined conversion-functional coating meets stricter commercial and U.S. and European Union environmental mandates, avoiding the concerns with prohibited products using toxic hexavalent chromates.
Results of tests to ASTM standards demonstrate salt-spray protection up to 168 hours on Aluminum alloy 380.
(For a printed CWM "Tech Brief" on the latest information regarding Trivalent Chromium coating for die castings, contact your CWM Regional Sales-Engineering Representative or the CWM Sales Dept., or download Tech Brief No. 34 in the Application/Tech Brief section of the OEM Resource Center)
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