Tool- Design - Manufacturing

Perfect casting is as much an art as a skill. We are one of the few pressure die casters that strive for blemish-free production. Every component at Accent die casting & fixtures manufactured to these same high standards – whether it is ultimately to be powder coated, painted, plated or left nude.

Achieving perfection requires harmony between the tool design, equipment, caster and the countless other variables that affect a casting’s internal and external structure. If one item is not in balance then the casting will be substandard, and will be exposed when it comes to finishing.

The perfect casting starts with the design of the component. Seemingly insignificant changes can have a material effect on casting, resulting in higher quality production and lower cost manufacture. Once the component is optimized, the tool is designed with flow analyses of the wave structure so as to ensure it is completely filled. Any mistake, however small, will allow misruns or cold flows to mar the surface finish and cause porosity levels to increase, weakening the component’s structure and causing micropores or fissures to develop.

After so many years we know what it takes to achieve the perfect casting. It’s having craftsmen with an innate understanding of the processes and the ability to get the most out of the highest quality equipment. That is why we’re one of the best in the business.

Accent Tool Design

Tool design is crucial to achieving the perfect casting and the perfect coating. All our tools start with design stage, where we talk with our customers to make sure any shortfalls for the part can be vetted and corrected before the tool is built. During this phase we can also predict where the tool will wear and create removable inserts for the tool that can save time and maintenance. We design our tools to run with minimal downtime.

We apply state-of-the-art computational 3D fluid dynamics analysis to optimize the positioning of the inflow and outflow gates- vital to being able to achieve the correct filling speed. This is the key to maintain a low porosity casting. In order to ensure a perfect finish, the surface coating needs a degree of texture to grip on to, so the tool must be machined to just the right extent- not too rough, not too smooth.

The Accent tooling division is comprised of experienced and skillful tool makers whose expertise make big difference in the quality when it comes to customizing tools for the customers. Not only do they make the best die cast tools but their combine exposures of works with thousands of customers from nearly every industry can find effective solutions if any issues arise during the production process.

Surface Finishes & Plating

There is a proverb in the casting world-`start with the finish in mind.’ It implies that the specific design features of a die cast part, in general, has a direct impact on achieving the required surface finish specifications.

External surface plating is applied to components if the parts require a decorative finish and corrosion resistance. But for the plating to be effective and long lasting the item must have good surface finish.

We refine every aspect of the casting and finishing process so that every component is properly prepared for the required coating – this is vital to achieving defect-free production. We design tools that produce an immaculate surface for coating; employ the finest machining techniques to hone the surface; and then utilize the most appropriate plating and coating materials to achieve an immaculate result.

With the full range of machining and coating equipment and our unparalleled knowledge of the finishing industry, we offer an exclusive service to companies that require perfection every time.

Leak Testing

Leaking castings has always been the weak spots for ordinary die casters, but not at Accent. Our commitment to fabricate pressure tight castings has led us to become the forerunner in this field. We have installed special instruments to evaluate the degree of leakage in our castings.

What is leakage

A leak is a flow of gas (or liquid) through the wall of a vessel (via an imperfection such as a hole, crack or bad seal). Leaks require a pressure difference to generate the flow; they always flow from higher pressure to lower pressure.

Either porosity or surface issues in the parts create leak paths from the inside to the outside of a casting. Preventing the existence of these defects is an effort in process control.

We are using `pressure decay leak tester’ to detect leaking castings. The advantage of pressure decay testing is its relatively quick test cycle. Pressure decay testing measures the change in pressure between atmospheric pressure and the pressurized test sample. Unlike some other current methods of leak testing, this test method yields quantitative information, hard data points that can be recorded and upon which decisions can be made. This removes the dependency upon the operator and allows specific accept/reject criteria to be set, and this method is quite simple to use. It is fast; 2-4 second cycles are achievable, keeping in mind that test time is volume dependent. Pressure decay testing is as sensitive as the time available for the test.