“When the plunger moves we can’t do anything any longer”, “throughout quick shot we can accelerate and decrease the plunger up to 5 times”, “when we have excellent castings we make a temperature image and determine the plunger speeds. If we get quality issues we simply go back exactly what we recorded to make good castings once again”. 3 statements I spoke with a die casting device offered by a good Die Casting Manufacturer, a die casting maker offered by a good Die Casting Manufacturer vendor and a teacher. What did I learned from it? There is a kernel of reality in all statements.
The very first scenario is exactly what we see the most in the industry. The shot is set and examined with tracking systems. Casting bad quality the set up will be altered, sometimes the criterion are kept and utilized for future production runs.
Criterion changing throughout fast shot is not utilized at all. The closes to this doing is the plunger deceleration at end of fast shot to minimize plunger impact load at end of fill. There are a number of reasons this opportunity is not utilized in more details. Velocity reduction lowers the force behind the melt and fronts would not merge producing cold runs. Too it increases the fill time resulting in chillier melt and cold runs. Variations in the poured melt volume develop discrepancies in between switch ranges and melt fronts. In other words we have an unstable procedure.
So and why is the third method not working? Inspecting plunger speeds is a simple task and performed in numerous centers today. Determining the temperature is a lot more complicated. The electronic camera is very pricey and die casting machine offered by a good Die Casting Manufacturer shy away based upon the costs. The electronic camera is big and therefor can’t be directed to catch all areas of interest. Depending upon the angle the measured worths will change. To make images the production needs to be stopped and the die cools throughout capturing the temperature profile. As longer the methods around the maker and as more complicate the video camera position as further away is the measured temperature from the real temperature level. Change the die temperatures with water or oil consumptions through the channels in the die possibly not possible. Cooling a brand-new die is different to cool a die with scaling in the water channels. And on top there is more than temperature level and plunger switches the teacher informed me. Like clocking of wind vents, altering in clearances between components in a new and an old die. Not to discuss to keep the same plunger stroke however have a plunger with a different size. Or plain the die inserts at their surface areas for finding function and decrease eviction area at the very same time. Now the casting quality and shot parameter change even with the same plunger strokes and speeds.
As usual there is not a single service for the ideal process criterion set for the complete life of the die. With wear and tear of the die procedure specification may need to be changed. As more documentation is done and as more details the die casting device offered by a good Die Casting Manufacturer has at hand as much easier it will be to discover the optimized machine set up.
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